Chrysler Group LLC

Performance Standard
Category Code: D-1
EASL Requirement: No
Restricted: No

Document Number: PF-9497<S>

Date Published: 2012-03-29
Change Level: D

ULTRASONIC WELDING OF AUTOMOTIVE WIRING HARNESSES

1.0 GENERAL
1.1 Purpose
This standard describes the Ultrasonic Welding Requirements for all automotive wiring harnesses joined by
this process.
1.2 Coverage of this Standard
This standard is for use in supplying certain parts under purchase orders of Chrysler Group LLC or its
subsidiaries. This standard is limited in its application to those drawings or illustrations which call out this
standard number, or which refer to this standard within some other standard or specification. Original
equipment or replacement parts for some vehicles sold by Chrysler Group LLC or its dealers are not covered
by this standard.
A shielded section <S> in this standard applies to safety welds as designated on the welding releases. In
this situation, the safety weld must comply with the requirements of EM-10001<S> ("Shield" Requirements
- Corporate Assembly Plants), EM-10002<S> ("Shield" Requirements - Corporate "Internal Supplier"
Plants), and EM-10003<S> ("Shield" Requirements - "External" Supplier" Plants) as shown in the possible
conditions below:
Condition 1 - The weld drawing does not have a safety symbol on the weld, and there is no safety shield
on specific sections of the weld standard. Interpretation - For this specific non-safety shielded weld,
conformance to the above EM standards is not necessary for any conditions defined in non-safety
shielded sections of the weld standard. However, the weld standard requirements must still be met by this
weld.
Condition 2 - The weld drawing has a safety symbol on the weld, but there is no safety shield on specific
sections of the weld standard. Interpretation - For this specific safety shielded weld, conformance to the
above EM standards is not necessary for any conditions defined in non-safety shielded sections of the
weld standard. However, the weld standard requirements must still be met by this weld.
Conditions 3 - The weld drawing does not have a safety symbol on the weld, but there is a safety shield on
specific sections of the weld standard. For this specific non-safety shielded weld, conformance to the
above EM standards is not necessary for any conditions defined in safety shielded sections of the weld
standard. However, the weld standard requirements must still be met by this weld.
Condition 4 - The weld drawing has a safety symbol on the weld, and there is a safety shield on specific
sections of the weld standard. For this specific safety shielded weld, conformance to the above EM
standards is necessary for any conditions defined in safety shielded sections of the weld standard. The
weld must conform to both the "EM" standard's requirements and meet the weld standard's requirements.
Any deviation to the Supplier Quality lot control requirement as called out in EM-10001<S>, EM10002<S>, or EM-10003<S> must be approved by the Supplier Quality Office and the Product Releasing
Group.

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Special welding requirements specified in a purchase order shall be placed on the supplier's drawing or
welding release.
1.3 Limitations on Usage
This standard is applicable to all automotive wiring harnesses (consisting of multi strand copper wire cables)
that are joined by the ultrasonic welding process. Tin or solder plated wires shall not to be ultrasonic welded.
1.4 Requirements on Part Drawings
Any weld requirements designated on the detail assembly, weld only drawings or engineering releases are
dominant to and take precedence over the requirements specified within this standard.
1.5 Design Limitations
1.5.1 Number of Cables
The difference in the number of cables entering the splice from one direction relative to the number of cables
entering the splice from the opposite direction shall not exceed seven (7).
1.5.2 Total Number of Cables per Splice
The total number of cables in a splice shall not exceed eight (8).
1.5.3 Size of Cables in Splice
1.5.3.1 Difference Between Largest and Smallest Cables
The difference between the smallest and largest cable in a splice shall not exceed 4.5 mm (0.00697 in.).
1.5.3.2 Acceptable Cable Sizes
Only cables in the range of 0.35 mm (0.00054 in.) (22 ga) to 8.0 mm (0.0124 in.) (8 ga) shall be used.
1.5.4 Multi-Cable Splice
Where only one cable is to leave the end of a multi-cable splice, the minimum cable size shall be 1 mm
(0.00155 in.).
1.5.5 Minimum Distance Between Welded Splices
The minimum distance between welded splices in a harness shall be 30 mm (1.180 in.) as measured from
the weld center.
1.5.6 Bending of Wires at Splice
Wires leaving welded splices shall comply with the requirements of PF-10099, entitled "WIRING HARNESS
- ASSEMBLY PERFORMANCE".
1.5.7 Strip Length
A minimum strip length of 9 mm (0.354 in.) shall be used for a cross sectional area (CSA) less than 5 mm
(0.00775 in.), and a minimum strip length of 13 mm (0.512 in.) for a CSA greater than or equal to 5 mm
(0.00775 in.), where the CSA is the sum of all individual cable CSAs.

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1.6 Condition of the Cable Wires

The surface of the cable wires at the time of welding shall be free from oil, grease, soft coatings (tin, lead,
solder) or any other coatings that may adversely affect the weld quality.
To prevent oxidation of the copper wire the cable should be stripped just prior to the welding of the splice.
Not more than five (5) calendar days shall pass between wire stripping and welding operations.
1.7 Welding Set-Up Procedure Steps
- Measure compaction prior to welding on set-up parts.
- Weld set-up parts.
- Measure compaction after welding on set-up parts.
- Verify post-weld compaction height is less than the pre-welded compaction height. If it is not, check the
welding machine operation or possible errors in the set-up procedure.
2.0 REQUIREMENTS
2.1 Destructive Test Frequency
On the initial machine set-up and at intervals designated by the responsible Plant Department, Destructive
Tests shall be performed to determine the ultrasonic weld quality.
2.2 Weld Compaction
The finished weld compaction shall have a CSA of between 95% - 110% of the total original (prior to welding)
CSA of the constituent cables. Cables with a total CSA of greater than 24 mm (0.0372 in.) shall not be
ultrasonically welded.
2.3 Rewelding of Cable Splices
Rewelding of previously welded cable splices is not allowed by this standard.
2.4 Inspection Requirements
The primary objective of the following inspection procedures is to assure that adequate process control is
being employed. Inspection techniques to be used are visual inspection and physical destructive testing.
NOTE: All testing shall be done without the protective splice covering in place.
2.4.1 Visual Inspection
2.4.1.1 Missing Strand Allowance for Splices
The missing strand allowances for stripping cables are shown in Table 1.

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TABLE 1: MISSING STRAND ALLOWANCE

NUMBER OF STRANDS IN CABLE

ALLOWABLE MISSING STRANDS

From 2 to 7

None

From 8 to 14

Over 14

2.4.1.2 Cut or Loose Strands

The welded splice utilizing any cable core construction shall be visually inspected for cut or loose strands
resulting from the welding process. The welded splice shall not have any cut or missing strands greater than
that allowed for the missing strand allowance (see Table 1). No loose strands are acceptable after welding.
2.4.1.3 Length of Weld
The minimum length of weld shall not be less than 6.0 mm (0.236 in.).
2.4.2 Physical Destructive Testing <S>
Peel" or "Metallographic" test shall always be performed on the parts during setup to assure that machines
are in suitable condition for release to production and that the welding schedules are correct, and during
production at a regular frequency as determined by the appropriate Chrysler Quality Group and the
Manufacturing facility.
If the "Pull" test is selected, the "Tensile Strength Test" as called out in PF-10099 (WIRING HARNESS ASSEMBLY PERFORMANCE), should not be conducted.
2.4.2.1 Pull Strength
The pull strength shall be determined using the test fixture as shown in Figure 1. The pull speed shall be 50
mm/min.
Wire selection for the Pull Strength test shall be made by the following two step method:
Step 1: Select the smallest wire on each side (see example in Figure 2). (This is either Wire A or Wire B on
Side A, and Wire C on Side B.)

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FIGURE 1: PULL STRENGTH TEST AND FIXTURE

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FIGURE 2: PULL STRENGTH WIRE SELECTION

Step 2: Select a single wire on each side that is the closest to being co-linear with the selected wire on the
opposite side. (This requires selecting Wire C and Wire A, since they are closer to being co-linear than
are Wire C and Wire B.)
The pull strength shall not be less than that shown in Table 2 for the smallest cable in the splice.
TABLE 2: MINIMUM ACCEPTABLE PULL STRENGTH
SMALLEST CABLE SIZE

MINIMUM ACCEPTABLE PULL STRENGTH

N (lbs)

0.35 mm (22 ga)

67 (15)

0.5 mm (20 ga)

89 (20)

0.8 mm (18 ga)

111 (25)

1.0 mm (16 ga)

133 (30)

2.0 mm (14 ga)

267 (60)

3.0 mm (12 ga)

311 (70)

5.0 mm (10 ga)

356 (80)

8.0 mm (8 ga)

400 (90)

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2.4.2.2 180 Peel Strength

The wire to be peeled shall be at the top of the splice stack that has been welded (see Figure 3).
The cable to be peeled shall be

from the lay of the splice.

The minimum acceptable 180 peel strength is shown in Table 3.

2.4.2.3 Metallographic Inspection
Micro-examination shall be used for arbitration of fusion adequacy in the event that weld fusion cannot be
o
positively established by the Pull or the 180 Peel test.
2.4.2.4 Micro-examination
The weld fusion shall be examined on an etched cross section through the welded splice. All wires shall
show fusion to adjacent wires except for the allowance allowed in section 2.4.1.2 (Cut or Loose Strands) of
this standard. The minimum acceptable fusion between adjacent wires is 15% of the smallest wires original
surface diameter.

FIGURE 3: 180

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2.5 Tool Size Requirements

Example: Assume three 14 gage wires enter one side of the weld area and that a single 12 gage wire enters
the weld area from the other side. The three 14 gage wires have an individual CSA of 2 mm, while the 12
gage wire has an individual CSA of 3 mm. The total CSA is calculated as follows:

2.6 Process Potential Study

At initial production start-up of the process, the supplier, in conjunction with Chrysler Quality Specialist, shall
perform a Process Potential Study. Refer to Chrysler's SQA manual Guide to Quality Systems
Requirements.
TABLE 3: MINIMUM ACCEPTABLE 180 PEEL STRENGTH
CABLE SIZE

MINIMUM ACCEPTABLE PEEL STRENGTH

N (lbs)

0.35 mm (22 ga)

11 (2.5)

0.5 mm (20 ga)

15 (3.4)

0.8 mm (18 ga)

18 (4.0)

1.0 mm (16 ga)

22 (4.9)

2.0 mm (14 ga)

60 (13.4)

3.0 mm (12 ga)

90 (20.1)

5.0 mm (10 ga)

110 (24.6)

8.0 mm (8 ga)

140 (31.3)

2.7 Process Capability Study

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Following successful completion of the process potential study, a process capability study shall be performed.
Refer to Chrysler's SQA manual Guide to Quality Systems Requirements.
2.8 Quality
Refer to CS-9801 for general quality requirements.
The supplier must have a quality assurance program in effect assuring compliance to Chrysler's quality
requirements specified within the quote package, Chrysler's SQA manual Guide to Quality Systems
Requirements, applicable Engineering Standards, and part drawings. The supplier's control plan shall assure
that initial production shipments and those made subsequently through the year meet Chrysler's
requirements. Volume production must conform to Chrysler specifications and meet or exceed quality and
performance levels of the most recent samples approved by Chrysler.
3.0 CONTROL
Requests for changes to this standard should be forwarded to the responsible activity issuing the standard.
Any changes in processing must be approved in writing by Chrysler group LLC, Engineering Office, Body
Materials Engineering.
This process shall only be purchased from those sources appearing on the Chrysler PASL. For further
information contact Chrysler's Purchasing Office.
A supplier who furnishes parts to Chrysler is responsible for the quality of all components of the shipped
assembly or end item; whether component parts are processed/manufactured by him or purchased from
another source.
4.0 QUALITY
Refer to CS-9801 for general quality requirements.
5.0 DEFINITIONS/ABBREVIATIONS/ACRONYMS
Cable: The encapsulated multi strand copper wire capable of carrying electrical current.
CSA: An abbreviation for cross sectional area.
Multi-Cable Joint: A multi-cable joint is a splice containing more than two (2) cables.
Splice: The joined intersection of two or more cables.
Ultrasonic Welding (USW): A solid-state welding process that produces a weld by the local application of
high frequency vibratory energy as the workpieces are held together under static force.
6.0 GENERAL INFORMATION
Three asterisks *** after the section/paragraph header denotes single or multiple technical changes to
the section/paragraph. Specific technical changes within a section, subsection, table, or figure may be
highlighted in yellow.
Certain important information relative to this standard has been included in separate standards. To
assure the processes submitted meet all of Chrysler requirements, it is mandatory that the requirements in
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the following standards be met.

CS-9800 - Application of this standard, the subscription service, and approved sources
CS-9003 - Regulated substances and recyclability
Within Engineering Standards, the Regulatory (Government-mandated) requirements are designated by
<S> and <E> which correspond to Safety and Emission Shields respectively. When applicable, the
Chrysler mandated requirements are designated by <D> which correspond to the Diamond symbol and by
<A> for Appearance related objectives, respectively.
For specific information on this document, please refer to the contact person shown in the "Publication
Information" Section of this document. For general information on obtaining Engineering Standards and
Laboratory Procedures, see CS-9800 or contact the Engineering Standards Department at
engstds@chrysler.com.
7.0 REFERENCES
Chrysler
ASTM
Standards
Standards
CS-9003
CS-9800
CS-9801
EM-10001<S>
EM-10002<S>
EM-10003<S>
PF-10099
PF-SAFETY <S>
Quality and Reliability Documents

ISO
Standards

SAE
Standards

Federal
Standards

Other Documents

8.0 ENGINEERING APPROVED SOURCE LIST

Not applicable
9.0 PUBLICATION INFORMATION
Contact/Phone Number: Igor Rimmer, 248.512.4693
Alternate Contact/Phone Number: Joseph Beckham, 248.512.6498
Department Name & Department Number/Tech Club/Organization: Joining Technologies, Materials
Engineering-Welding, Dept. 5850
Date Standard Originally Published: 1994-05-03
Date Published: 2012-03-29
Change Notice:
Description of Change:
- Update format
- Update contact names
#####

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Copyright Chrysler Group LLC