INTERNATIONAL ISO STANDARD 15609-5 First edition 2004-08-01 Specification and qualification of welding procedures for metallic materials — Welding procedure specification — Part 5: Resistance welding Descriptif et qualification d'un mode opératoire de soudage pour les ‘matériaux métallques — Descriptf un mode opératoire de soudage Partie 5: Soudage par résistance Reference number 's0 15609-5:2004(E) © 180 2004ISO 15609-5:2004() POF disclaimer This POF fle may contain embedded typefaces. In accordance with Adobe's Koasing picy ths fle may be print or ved but hal rot be eet Untess the ypofaces when are embedded are leenoed to and Instated onthe compar petomang he eng, downioacing this fe, pares accep theron the responsibly oF not Iinging Adobe's Hoonsing poly. 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Every care has been laken to enstie that the Sef sutabe for use by ISO momber Doses. lh {he unikely event that a problan ralatng to fs un, please infor the Conval Secretaria atthe adress ghen below © 180.2008 Al rights reserve, Unless otherwise specied, no pat of his publation may be reproduced or uiized in any form or by any means, ‘laconic of mechanical, including photocopying and microfim, wibout permission in wring Wom ether ISO at the address below of 180's member body in the country ofthe requester, 1S0 copyright ofce Case porala 86» CH-1211 Genava 20 Tat #4022 76001 11 Fax +4122 749 0047 Erma eopyrgnaico or ‘We vac isa. org Published in Switzeand ii (© 180.2004 All ghts reservedISO 15609-5:2004(E) Foreword ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies (ISO member bodies). The work of preparing International Standards is normally carried aut through ISO technical committees. Each member body interested in a subject for which a technical committee has been ‘established has the right to be represented on that committee, international organizations, governmental and non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization. International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2. ‘The main task of technical committees Is to prepare Intemational Standards. Draft International Standards adopted by the technical committees are circulated to the member bodies for voting. Publication as. an International Standard requires approval by atleast 75 % of the member bodies casting a vote ‘Attention is drawn to the possibilty that some of the elements of this document may be the subject of patent rights. ISO shall not be held responsible for identying any or all such patent rights. ISO 15614-12 was prepared by the European Committee for Standardization (CEN) in collaboration with Technical Committee ISO/TC 44, Welding and allied processes, Subcommittee SC 10, Unification of requirements in the field of metal welding, in accordance with the Agreement on technical cooperation between ISO and CEN (Vienna Agreement) ‘Unroughout the text of this document, read *..this European Standard... to mean * Standard..." his. International 1S0 15644 consists of the following parts, under the general tite Specification and qualification of welding procedures for metallic materials — Welding procedure test. Part 1: Are welding — Part 2: Gas welding — Part 3: Electron beam welding — Part 4: Laser beam welding — Part §: Resistance welding ‘Annex ZA provides a list of corresponding International and European Standards for which equivalents are not given in the text. (© 180 2008 At rigs reserved iiContents Page Foreword. Introduction... 1 Scope 2 Normative references... 3 Terms and definitions 4 Technical contents of welding procedure specification (WPS). 4.1 General. 42 Related to manufacturer .. 43 Related to parent material 4.3.4 Composition of parent material 432 Dimension of parent material 4.4 Common to all welding procedures. 4.44 Welding process. 4.42 Machine specification 443 Joint design 444 Surface or edge preparation 445 Welding technique.. 4.48 Resistance welding electrodes and auxiliar 4.4.7 Machine parameters and control settings Annex A (informative) Welding procedure specification - | - Planned process requirements. Annex B (informative) Welding procedure specification - Il - Quality acceptance criteria Annex C (informative) Welding procedure specification - Ill - Welding machine set-up ‘Annex ZA (normative) Normative references to International publications with thelr relevant European publications. Bibliography. v (©180 2004 A ight reserved180 15609-5:2004() 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) (0180 2008 As rights rsarved vIso 15609-! 1004(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. vi 6180 2008 At rights reserved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 acceptabllty 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 ofthis series are given in EN 1SO 15607:2003, annex A. Variables listed in this standard are those influencing ether weld dimensions (quality), weld nugget dimension, weld pattern positioning, mechanical properties or geometry ofthe 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 §163-1:1998) EN ISO 5183-2, Resistance spot welding — Electrode adeptors, 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 156072003, 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 827: 1983) EN 28430-1, Resistance spot welding — Electrode holders — Part 1: Taper fixing 1:10 (ISO 8430-1: 1988). EN 2840-1 Resistance spot welding — Electrade 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: 1986). 180 669:2000, Resistance welding — Resistance welding equipment — Mechanical and electrical requirements, (© 180.2008 Alright eserves 1ISO 15609-5:2004(E) 3. Terms and defini ns 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) 41 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 44, 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 (WPOR). 4.3 Related to parent material 43.1 Composition of parent material —— Designation of the material(s) and referenced standards); — Incase 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 444 Welding process Welding process(es) specified shall be designated as listed in EN ISO 4063: a). Spot welding (21) 2 1©180 2004 ~All gh reservedISO 15609-5:2004(E) — manual — machine; eon multi: — direct; Indirect, — push-pul; — series. — mechanized: — single stage; — transfer tine — automatic feed: — robotic b) Seam welding (22) (Roller spot welding): — manual/guided/automaticrobotic. ©) Projection welding (23): — singlofmutipe: — embossedisolid 4). Resistance butt wolding (25): — resistancemashicapacitor discharge. @) Welabonding: — manual/mechanizedirobotic. NOTE Numbers in accordance with EN SO 4063, 442 Machine specification ‘Type of machine used and Identification (serial number, plant number or nameplate in accordance with ISO 669) 443° 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. 180 2008 ~ Alright reserved 3-2004(E) NOTE A sketch can be used showing he jin design/contguraton. 44.4 Surface or edge preparation degreasing, wire brushing, chemical etching, et. for butt welding, any mechanical edgeijint-face preparation (89, facing finishing): for spot, seam and projection welding any removal of edge burrs to avoid shunting 44.5 Welding technique ‘manuel, multi, mechanized, robotic welding; access details, weld sequence andlor pattern and gun angle or atitude; ‘work holding, clamping or quidance systems, tack welding, etc; procedures to minimize distortion, indentation, contamination, corrosion, et. (e. electrodes, shielding gas). use of face or backing NOTE Operator protection should be taken into consideration. 4.4.8 Resistance welding electrodes and auxiliaries. shape, dimensions and material composition of electrades, 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 6205-2; — applicable tolerances for the maintenance of the specified quality requirements, see EN 2430-1 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.9. 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); — wold force: magnitude and program where necessary; — weld current program: up-slope, down-stope, constant current contro: — seam welding speed curing in the current on time; — heat treatment; 4 ©180 2004 Aris overs10 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 mult-spot or projection welding); — cooling requirements for machine/transformer and electrodes; — heat setting (phase shit) and transformer tap setting, NOTE For further information see EN ISO 14327. (© 1802004 Alright reserved 5ISO 15609-5:2004(E) Annex A (informative) Welding procedure specification - Issue/Revision: - Planned process requirements No.: No. of welding procedure specification for next Date: ‘operational sequence for this jin/assembly: ‘Customer —__ —— nae ‘Manufacture Product Description: Quality requirements: ‘Assembly name: ‘Joint locationioperation ‘Numberfidentification code "” Product identification No. ‘Assembly No." Joint type: Parent material Form: ‘Surface condition: ‘Weld pattem/sequence (sketch) ‘Number of welds per joint Quality acceptance specification’ annex 8 Procedure specification Type: Welding rate (weld/min) Environmental constraints: Location: ‘Machine identification No.: Machine type: : ‘Manual/mecranizediautomated: Machine size/eapacity: Electrode set-up 7 “Tooling ‘Special services needed: = Electrode change/dressing program: annex C ‘Machine control type: Electrode holder driled/not drilled: Machine control identification number. ‘Auxiliary services: “Type of actuator (air cylinder) = ‘Seam and roller spot welding: ‘Seam welding speed during inthe courrent on time (m/min: ‘Seam welding speed during in the current off time (m/min): "Insert drawing number Control settings (program) chart No. Welding current form: ‘Monitor type: Welding current KAY: ‘Secondary voltage (V} “Flectrode force (kN): Forge force: ‘Cooling typerfiow rate (Umin) Specified post-weld treatment annex Postweld treatment equipment (© 180.2004 -Atghts reservedEnter identification letter from chart, €.g ‘SP = pedestal spot weld equipment, PW = projection weld equipment; CG = portable C-gun; MW = muttweld equipment; SG = portable scissor gun; PS = portable seam weld equipment; RW. = welding robot; SW = seamweld equipment. ‘optional subgroups: D- = dual stroke: H hydraulic; s soft descent; A other (2. g. electromagnetic), “os single stroke; D dual stroke; Pp diaphragm; R flow restrictors, Special instructions: Prepared by: Date: (©1S0.2008 Al ights reserved1SO 15609-5:2004(E) Annex B (informative) Welding procedure specification - Il - Quality acceptance criteria No. {sgue/Revision: Dat Customer: Manufacturer _ Product - Description! Product identification No, ‘Assembly name: ‘Assembly No, ‘Joint lacationloperation ‘Joint type: humberiidentfication code " : Quality requirements. Product ‘Type of weld: Welds quality rating ‘Appearance’ Geometrical and physical properties of joint min. | min. weld | fracture Specified test values value value | diameter | type (mm) gen) (nm Nugget diameter (nin: Ghisel test: I ‘Nugget indentation (min max. Peel force: Electrode indendation diameter (nominal) ‘Shear forces: C Electrode indentation depth (max. Cross tension force: ‘Sheet separation (max. Impact force: Fatigue force (KN) and oycles: ‘Special instructions: Corrosion test Prepared by: Date: insert drawing number (© 150.2004 —Allights reservedISO 15609-5:2004(E) Annex C (informative) Welding procedure specification - Ill - Welding machine set-up Issue/Revision: Date: ‘Customer Manufacturer Product. Description! ‘Assembly namie: ‘Joint location/operation humberiidentification code " i ‘Machine/Gun type: Platen/electrode dimension (mm). “Transformer rating (kVA): No.: Product identification No. ‘Assembly No. ‘Joint type: Machine identification No, ‘Secondary cable/shunt size (wm x mm): Secondary cable(s) type x length (m): Tap No. “Transformer identification No. ‘Control timer/programmer: Control timer/programmer identification No: Cylinder type: Tooling High if Cooling typeffiow rate (min Electrode setup ‘Check of auxiliaries: Electrode approach rate (m/min) ‘Source of start signal Electrode force (kN). End of cycle trigger signal ‘Safety guard: “Throat dimensions: Location (work station) Weld control parameters Pre-squeeze tme {cycles with 50 of 60 periods): “Squeeze time (cycles) ‘Number of pulsation ‘Weld time (cycles): ‘Weld current (kA\: ‘Offtime (cycles): Heat setting: Repeat weld time (eyelas Up-slope: Hold tme (cycles): Down-slops: Off time (cycles): Recorder active! ‘Monitor type: ‘Stepper control aclve: ‘Stepper control lype ‘Stepper control program: Machine/tooling ‘Machine control setings: ‘Conditions of auxiliary services: Post-weld treatment: z Special instructions: Prepared by: Date: "Insert drawing number (© 150.2008 ~All ght emserved Condition of electrodes: Condition of tooling1SO 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 Intemational Publication has been modified by common mosifistions, indicated by (mod.), the relevant ENIHD apples Publication Iso 5184 so 5821, 180 5827 1S0 8430-1 180 8430-2 180 8430-3 10 Year 1979 1979 1988 Tite Straight resistance spot welding electrodes Resistance spot welding, electrode caps ‘Spot welding — Electrode back-ups land clamps. Resistance spot ___welding — Electrode holders — Part 1: Taper foxing 1:10 Resistance spot _welding — Electrode holders — Part 2: Morse taper fixing Resistance spot welding — Electrode holders — Part 3: Parallel shank fixing for end thrust EN 25184 EN 25821 EN 25827 EN 28430-4 EN 28430-2 EN 28430-3 Year 1904 1991 1992 1992 1992 1992 (© 180.2008 - Al ight reservesISO 15609-5:2004(E) Bibliography EN ISO 14327, Resistance welding — Procedures for determining the weldabiliy lobe for resistance spot, projection and seam welding (ISO 14327: 2004). (© 180 2004 Alright reserved "Ics 25.160.10 ce bated on 11 pages © 180 2004 — Alights reserved