BS EN ISO 15609-5：2004 Resistance Welding

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25 February 2005

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BRITISH STANDARD

Specification and qualification of welding procedures for metallic materials — Welding procedure specification — Part 5: Resistance welding

The European Standard EN ISO 15609-5:2004 has the status of a British Standard

ICS 25.160.10

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BS EN ISO 15609-5:2004

BS EN ISO 15609-5:2004

National foreword This British Standard is the official English language version of EN 15609-5:2004. It is identical with ISO 15609-5:2004. The UK participation in its preparation was entrusted to Technical Committee WEE/36, Approval testing of welding procedures and welders, which has the responsibility to: —

aid enquirers to understand the text;

—

present to the responsible international/European committee any enquiries on the interpretation, or proposals for change, and keep the UK interests informed;

—

monitor related international and European developments and promulgate them in the UK.


A list of organizations represented on this committee can be obtained on request to its secretary. Cross-references The British Standards which implement international or European publications referred to in this document may be found in the BSI Catalogue under the section entitled “International Standards Correspondence Index”, or by using the “Search” facility of the BSI Electronic Catalogue or of British Standards Online. This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations.

Summary of pages This document comprises a front cover, an inside front cover, the EN ISO title page, pages 2 to 15 and a back cover. The BSI copyright notice displayed in this document indicates when the document was last issued. This British Standard was published under the authority of the Standards Policy and Strategy Committee on 11 August 2004

© BSI 11 August 2004

ISBN 0 580 44258 6

Amendments issued since publication Amd. No.

Date

Comments

EUROPEAN STANDARD

EN ISO 15609-5

NORME EUROPÉENNE EUROPÄISCHE NORM

August 2004

ICS 25.160.10

English version


Specification and qualification of welding procedures for metallic materials - Welding procedure specification - Part 5: Resistance welding (ISO 15609-5:2004) Descriptif et qualification d'un mode opératoire de soudage pour les matériaux métalliques - Descriptif d'un mode opératoire de soudage - Partie 5: Soudage par résistance (ISO 15609-5:2004)

Anforderung und Qualifizierung von Schweißverfahren für metallische Werkstoffe - Schweißanweisung - Teil 5: Widerstandsschweißen (ISO 15609-5:2004)

This European Standard was approved by CEN on 16 January 2004. CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the Central Secretariat or to any CEN member. This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the Central Secretariat has the same status as the official versions. CEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.

EUROPEAN COMMITTEE FOR STANDARDIZATION COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG

Management Centre: rue de Stassart, 36

© 2004 CEN

All rights of exploitation in any form and by any means reserved worldwide for CEN national Members.

B-1050 Brussels

Ref. No. EN ISO 15609-5:2004: E

EN ISO 15609-5:2004 (E)

Contents

Page

Foreword..............................................................................................................................................................3


Introduction .........................................................................................................................................................4 1

Scope ......................................................................................................................................................5

2

Normative references ............................................................................................................................5

3

Terms and definitions ...........................................................................................................................6

4 4.1 4.2 4.3 4.3.1 4.3.2 4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.4.7

Technical contents of welding procedure specification (WPS) ........................................................6 General....................................................................................................................................................6 Related to manufacturer .......................................................................................................................6 Related to parent material.....................................................................................................................6 Composition of parent material............................................................................................................6 Dimension of parent material ...............................................................................................................6 Common to all welding procedures.....................................................................................................6 Welding process ....................................................................................................................................6 Machine specification ...........................................................................................................................7 Joint design............................................................................................................................................7 Surface or edge preparation.................................................................................................................8 Welding technique .................................................................................................................................8 Resistance welding electrodes and auxiliaries ..................................................................................8 Machine parameters and control settings ..........................................................................................8

Annex A (informative) Welding procedure specification - I - Planned process requirements ..................10 Annex B (informative) Welding procedure specification - II - Quality acceptance criteria........................12 Annex C (informative) Welding procedure specification - III - Welding machine set-up ...........................13 Annex ZA (normative) Normative references to International publications with their relevant European publications ........................................................................................................................14 Bibliography ......................................................................................................................................................15

2

EN ISO 15609-5:2004 (E)

Foreword This document (EN ISO 15609-5:2004) has been prepared by Technical Committee CEN/TC 121 “Welding”, the secretariat of which is held by DIN, in collaboration with Technical Committee ISO/TC 44 “Welding and allied processes”. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by February 2005, and conflicting national standards shall be withdrawn at the latest by February 2005.


Annexes A, B and C are informative. According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom. NOTE

Normative references to International Standards are listed in annex ZA (normative).

3

EN ISO 15609-5:2004 (E)

Introduction All new welding procedures issued and the procedure for their creation and qualification are to be in accordance with this standard for the date of its issue.


This standard does not, however, invalidate welding procedures and their qualification complying with then existing national or international standards or regulations, provided the intent of the technical requirement is satisfied and the specified application remains unchanged.

4

EN ISO 15609-5:2004 (E)

1

Scope

This standard specifies requirements for the content of welding procedure specifications for resistance spot, seam, butt and projection welding processes. The acceptability of applying the principles of the standard to other resistance and related welding processes should be established before any qualification is undertaken. This standard is part of a series of standards. Details of this series are given in EN ISO 15607:2003, annex A. Variables listed in this standard are those influencing either weld dimensions (quality), weld nugget dimension, weld pattern positioning, mechanical properties or geometry of the welded joint.

2

Normative references


The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN ISO 4063, Welding and allied processes — Nomenclature of processes and reference numbers (ISO 4063: 1998). EN ISO 5183-1, Resistance welding equipment - Electrode adaptors, male taper 1:10 - Part 1: Conical fixing, taper 1:10 (ISO 5183-1:1998) EN ISO 5183-2, Resistance spot welding — Electrode adaptors, male taper 1:10 — Part 2: Parallel shank fixing for end-thrust electrodes (ISO 5183-2: 2000). EN ISO 8205-1, Water-cooled secondary connection cables for resistance welding — Part 1: Dimensions and requirements for double-conductor connection cables (ISO 8205-1: 2002). EN ISO 8205-2, Water-cooled secondary connection cables for resistance welding — Part 2: Dimensions and requirements for single-conductor connection cables (ISO 8205-2: 2002). EN ISO 15607:2003, Specification and qualification of welding procedures for metallic materials — General rules (ISO 15607: 2003). EN 25184, Straight resistance spot welding electrodes (ISO 5184: 1979). EN 25821, Resistance spot welding electrode caps (ISO 5821: 1979). EN 25827, Spot welding — Electrode back-ups and clamps (ISO 5827: 1983). EN 28430-1, Resistance spot welding — Electrode holders — Part 1: Taper fixing 1:10 (ISO 8430-1: 1988). EN 28430-2, Resistance spot welding — Electrode holders — Part 2: Morse taper fixing (ISO 8430-2: 1988). EN 28430-3, Resistance spot welding — Electrode holders — Part 3: Parallel shank fixing for end thrust (ISO 8430-3: 1988). ISO 669:2000, Resistance welding — Resistance welding equipment — Mechanical and electrical requirements.

5

EN ISO 15609-5:2004 (E)

3

Terms and definitions

For the purposes of this European Standard, the terms and definitions given in EN ISO 15607:2003 and ISO 669:2000 apply.

4

Technical contents of welding procedure specification (WPS)

4.1

General

The welding procedure specification (WPS) shall provide all the necessary information required to make a weld. The minimum information required in a WPS for resistance welding processes is listed in clause 4.2 to 4.4.


Welding procedure specifications shall apply to one specific application only, and the acceptability of expansion to cover similar applications shall be established before any qualification is undertaken. For some applications it may be necessary to supplement the list. All relevant information shall be specified in the WPS. Tolerance ranges shall be specified. Examples of the WPS format are shown in annexes A, B and C; these forms should be modified according to actual practice.

4.2

Related to manufacturer



Identification of manufacturer;



Identification of WPS;



Reference to the Welding Procedure Qualification Record (WPQR).

4.3

Related to parent material

4.3.1

Composition of parent material



Designation of the material(s) and referenced standard(s);



In case of anticorrosion coating (type, thickness, number of faces).

4.3.2

Dimension of parent material



Thickness of material at the joint;



Dimensions of cross-section of pipe or section (butt welding).

4.4

Common to all welding procedures

4.4.1 

Welding process

Welding process(es) specified shall be designated as listed in EN ISO 4063:

a) Spot welding (21):

6

EN ISO 15609-5:2004 (E)

 manual: 

machine;



gun.

 multi: 

direct;



indirect;



push-pull;



series.


 mechanized: 

single stage;



transfer line;



automatic feed;



robotic.

b) Seam welding (22) (Roller spot welding): 

manual/guided/automatic/robotic.

c) Projection welding (23): 

single/multiple;



embossed/solid.

d) Resistance butt welding (25): 

resistance/flash/capacitor discharge.

e) Weldbonding:  NOTE

4.4.2

manual/mechanized/robotic. Numbers in accordance with EN ISO 4063.

Machine specification

Type of machine used and identification (serial number, plant number or nameplate in accordance with ISO 669). 4.4.3

Joint design

The overlap, edge conditions, spot weld pitch, sequence and pattern, spot or projection dimensions, which depend on the sheet thickness, shall be specified and shall comply with the appropriate standards, where applicable.

7

EN ISO 15609-5:2004 (E)

NOTE

4.4.4

Surface or edge preparation



degreasing, wire brushing, chemical etching, etc.;



for butt welding, any mechanical edge/joint-face preparation (e.g. facing, finishing);



for spot, seam and projection welding any removal of edge burrs to avoid shunting.

4.4.5


A sketch can be used showing the joint design/configuration.

Welding technique



manual, multi, mechanized, robotic welding;



access details, weld sequence and/or pattern and gun angle or attitude;



work holding, clamping or guidance systems, tack welding, etc.;



procedures to minimize distortion, indentation, contamination, corrosion, etc. (e.g. use of face or backing electrodes, shielding gas).

NOTE

4.4.6

Operator protection should be taken into consideration.

Resistance welding electrodes and auxiliaries



shape, dimensions and material composition of electrodes, see EN 25184, caps see EN 25821, adaptors see EN ISO 5183-1 and EN ISO 5183-2;



shape, dimensions and material composition of backing electrodes, see EN 25827;



shape, dimensions and material composition of auxiliaries (e.g. electrode holders, cables, flexibles, shunts), see EN ISO 8205-1 and EN ISO 8205-2;



applicable tolerances for the maintenance of the specified quality requirements, see EN 28430-1, EN 28430-2 and EN 28430-3.

4.4.7

Machine parameters and control settings



welding current form: continuous alternating current, direct current, high-frequency, medium-frequency, or capacitor discharge, frequency converter;



welding current value(s) (current levels and number of pulses for pulse welding);



weld timing: squeeze and weld timing program (e.g. duration of pre-squeeze, squeeze, weld (heat, cool), number of pulses, hold, (off cycles) and post-weld heat treatment (annealing cycle));



secondary voltage readings (recorded for information only);



weld force: magnitude and program where necessary;



weld current program: up-slope, down-slope, constant current control;



seam welding speed during in the current on time;



heat treatment;

8

EN ISO 15609-5:2004 (E)



seam welding speed during in the current off time (for roller spot pitch, work piece transfer between spot welds, index for multi-spot or projection welding);



cooling requirements for machine/transformer and electrodes;



heat setting (phase shift) and transformer tap setting.


NOTE

For further information see EN ISO 14327.

9

EN ISO 15609-5:2004 (E)

Annex A (informative) Welding procedure specification - I - Planned process requirements


No.: ________ Issue/Revision: Date: Customer: Manufacturer: Product Description: Assembly name: Joint location/operation 1) Number/identification code : Parent material: Surface condition: Number of welds per joint: Procedure specification Type: Environmental constraints: Machine identification No.: Manual/mechanized/automated: 1) Electrode set-up : Special services needed: Machine control type: Electrode holder drilled/not drilled: Machine control identification number: Auxiliary services: Type of actuator (air cylinder): Seam and roller spot welding: Seam welding speed during in the current on time (m/min): Seam welding speed during in the current off time (m/min):

1)

Insert drawing number

10

No. of welding procedure specification for next operational sequence for this joint/assembly:

Quality requirements: 1) Product identification No. : 1) Assembly No. : Joint type: Form: 1) Weld pattern/sequence (sketch) : Quality acceptance specification:

**

Welding rate (weld/min): Location: Machine type: Machine size/capacity: 1) Tooling : Electrode change/dressing program: Control settings (program) chart No.: Welding current form: Monitor type: Welding current (kA): Secondary voltage (V): Electrode force (kN): Forge force: Cooling type/flow rate (l/min): Specified post-weld treatment: Post-weld treatment equipment:

annex B

*

annex C

annex C

EN ISO 15609-5:2004 (E)

*

Enter identification letter from chart, e.g.: SP = pedestal spot weld equipment; PW = projection weld equipment; CG = portable C-gun; MW = multiweld equipment; SG = portable scissor gun; PS = portable seam weld equipment; RW = welding robot; SW = seam weld equipment. optional subgroups: D = dual stroke; H = hydraulic; S = soft descent; n = other (e. g. electromagnetic).


**

S D P R

= = = =

single stroke; dual stroke; diaphragm; flow restrictors.

Special instructions: Prepared by: Date:

11

EN ISO 15609-5:2004 (E)

Annex B (informative) Welding procedure specification - II - Quality acceptance criteria

No.: ________


Issue/Revision: Date: Customer: Manufacturer: Product Description: Assembly name: Joint location/operation 1) number/identification code :

1)

Product identification No. : 1) Assembly No. : Joint type:

Quality requirements Product: Welds quality rating:

Type of weld: Appearance:

Geometrical and physical properties of joint Specified test values

min. value (kN) −

value (mm)

Nugget diameter (min.): Nugget indentation (min./max.): Electrode indendation diameter (nominal): Electrode indentation depth (max.): Sheet separation (max.):

Chisel test: Peel force: Shear force: Cross tension force: Impact force: Fatigue force (kN) and cycles:

Special instructions:

Corrosion test:

Prepared by: Date:

1)


12

min. weld fracture type diameter (mm)

EN ISO 15609-5:2004 (E)

Annex C (informative) Welding procedure specification - III - Welding machine set-up


No.: ________ Issue/Revision: Date: Customer: Manufacturer: Product Description: Assembly name: Joint location/operation 1) number/identification code : Machine Machine/Gun type: Platen/electrode dimension (mm): Transformer rating (kVA): Tap No.: Control timer/programmer: Cylinder type: High lift: 1) Electrode set-up : Check of auxiliaries: Electrode force (kN): Safety guard: Location (work station): Weld control parameters Pre-squeeze time (cycles with 50 or 60 periods): Squeeze time (cycles): Weld time (cycles): Off time (cycles): Repeat weld time (cycles): Hold time (cycles): Off time (cycles): Monitor type: Stepper control type: Machine/tooling Machine control settings: Conditions of auxiliary services: Post-weld treatment:

1)

Product identification No. : 1) Assembly No. : Joint type:

Machine identification No.: Secondary cable/shunt size (mm x mm): Secondary cable(s) type x length (m): Transformer identification No.: Control timer/programmer identification No.: 1) Tooling : Cooling type/flow rate (l/min): Electrode approach rate (m/min): Source of start signal: End of cycle trigger signal: Throat dimensions:

Weld current (kA): Heat setting: Number of pulsation: Weld current (kA): Heat setting: Up-slope: Down-slope: Recorder active: Stepper control active: Stepper control program: Condition of electrodes: Condition of tooling:

Special instructions: Prepared by: Date: 1)


13

EN ISO 15609-5:2004 (E)

Annex ZA (normative) Normative references to International publications with their relevant European publications


This European Standard incorporates by dated or undated reference, provisions from other publications. These normative references are cited at the appropriate places in the text and the publications are listed hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply to this European Standard only when incorporated in it by amendment or revision. For undated references the latest edition of the publication referred to applies (including amendments).

NOTE Where an International Publication has been modified by common modifications, indicated by (mod.), the relevant EN/HD applies.

Publication

Year

Title

EN

Year

ISO 5184

1979

Straight resistance spot welding electrodes

EN 25184

1994

ISO 5821

1979

Resistance spot welding, electrode caps

EN 25821

1991

ISO 5827

1983

Spot welding — Electrode back-ups and clamps

EN 25827

1992

ISO 8430-1

1988

Resistance spot welding — Electrode holders — Part 1: Taper fixing 1:10

EN 28430-1

1992

ISO 8430-2

1988

Resistance spot welding — Electrode holders — Part 2: Morse taper fixing

EN 28430-2

1992

ISO 8430-3

1988

Resistance spot welding — Electrode holders — Part 3: Parallel shank fixing for end thrust

EN 28430-3

1992

14

EN ISO 15609-5:2004 (E)

Bibliography


EN ISO 14327, Resistance welding — Procedures for determining the weldability lobe for resistance spot, projection and seam welding (ISO 14327: 2004).

15

BS EN ISO 15609-5:2004

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BS EN ISO 15609-5：2004 Resistance Welding

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