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BRITISH STANDARD
BS EN ISO
15609-5:2004
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
This British Standard was published under the authority of the Standards Policy and Strategy Committee on 11 August 2004
© BSI 11 August 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:
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.
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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.
Amendments issued since publication
EUROPEAN STANDARD
NORME EUROPÉENNE
EUROPÄISCHE NORM
EN ISO 15609-5
August 2004 ICS 25.160.10 English versionSpecification 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 soudagepour 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 C O M I T É E U R O P É E N D E N O R M A L I S A T I O N E U R O P Ä I S C H E S K O M I T E E F Ü R N O R M U N G
Management Centre: rue de Stassart, 36 B-1050 Brussels
© 2004 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members.
Contents
PageForeword...3
Introduction ...4
1 Scope ...5
2 Normative references ...5
3 Terms and definitions ...6
4 Technical contents of welding procedure specification (WPS)...6
4.1 General...6
4.2 Related to manufacturer ...6
4.3 Related to parent material...6
4.3.1 Composition of parent material...6
4.3.2 Dimension of parent material ...6
4.4 Common to all welding procedures...6
4.4.1 Welding process ...6
4.4.2 Machine specification ...7
4.4.3 Joint design...7
4.4.4 Surface or edge preparation...8
4.4.5 Welding technique ...8
4.4.6 Resistance welding electrodes and auxiliaries ...8
4.4.7 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
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.
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.
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.
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):
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:
manual/mechanized/robotic.
NOTE Numbers in accordance with EN ISO 4063.
4.4.2 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.
NOTE A sketch can be used showing the joint design/configuration.
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 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 Operator protection should be taken into consideration.
4.4.6 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;
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.
Annex A
(informative)
Welding procedure specification - I - Planned process requirements
No.: ________ Issue/Revision: No. of welding procedure specification for next
Date: operational sequence for this joint/assembly:
Customer: Manufacturer: Product
Description: Quality requirements:
Assembly name: Product identification No.1):
Assembly No. 1): Joint location/operation
Number/identification code 1) : Joint type:
Parent material: Form:
Surface condition: Weld pattern/sequence (sketch) 1):
Number of welds per joint: Quality acceptance specification: annex B Procedure specification
Type: Welding rate (weld/min):
Environmental constraints: Location:
Machine identification No.: Machine type: *
Manual/mechanized/automated: Machine size/capacity:
Electrode set-up 1): Tooling 1):
Special services needed: Electrode change/dressing program: annex C Machine control type: Control settings (program) chart No.:
Electrode holder drilled/not drilled: Welding current form: Machine control identification number: Monitor type:
Auxiliary services: Welding current (kA):
Type of actuator (air cylinder): ** Secondary voltage (V): Seam and roller spot welding: Electrode force (kN): Seam welding speed during in the Forge force:
current on time (m/min): Cooling type/flow rate (l/min):
Seam welding speed during in the Specified post-weld treatment: annex C current off time (m/min): Post-weld treatment equipment:
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 = single stroke; D = dual stroke; P = diaphragm; R = flow restrictors. Special instructions: Prepared by: Date:
Annex B
(informative)
Welding procedure specification - II - Quality acceptance criteria
No.: ________ Issue/Revision: Date: Customer: Manufacturer: Product
Description: Product identification No. 1):
Assembly name: Assembly No. 1):
Joint type: Joint location/operation
number/identification code 1) :
Quality requirements
Product: Type of weld:
Welds quality rating: Appearance:
Geometrical and physical properties of joint
Specified test values value
(mm) min. value (kN) min. weld diameter (mm) fracture type
Nugget diameter (min.): Chisel test: −
Nugget indentation (min./max.): Peel force: Electrode indendation diameter (nominal): Shear force:
Electrode indentation depth (max.): Cross tension force:
Sheet separation (max.): Impact force:
Fatigue force (kN) and cycles:
Special instructions: Corrosion test:
Prepared by: Date:
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: Product identification No. 1):
Assembly name: Assembly No. 1):
Joint type: Joint location/operation
number/identification code 1): Machine
Machine/Gun type: Machine identification No.:
Platen/electrode dimension (mm): Secondary cable/shunt size (mm x mm): Transformer rating (kVA): Secondary cable(s) type x length (m):
Tap No.: Transformer identification No.:
Control timer/programmer: Control timer/programmer identification No.:
Cylinder type: Tooling 1):
High lift: Cooling type/flow rate (l/min):
Electrode set-up 1) : Electrode approach rate (m/min):
Check of auxiliaries: Source of start signal:
Electrode force (kN): End of cycle trigger signal:
Safety guard: Throat dimensions:
Location (work station): Weld control parameters
Pre-squeeze time Weld current (kA):
(cycles with 50 or 60 periods): Heat setting:
Squeeze time (cycles): Number of pulsation:
Weld time (cycles): Weld current (kA):
Off time (cycles): Heat setting:
Repeat weld time (cycles): Up-slope:
Hold time (cycles): Down-slope:
Off time (cycles): Recorder active:
Monitor type: Stepper control active:
Stepper control type: Stepper control program:
Machine/tooling
Machine control settings: Condition of electrodes: Conditions of auxiliary services: Condition of tooling: Post-weld treatment:
Special instructions: Prepared by: Date:
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 weldingelectrodes 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 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).
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