CEN/TC 121/SC 1 Specification and qualification of welding

procedures for metallic materials

Secretariat CEN/TC 121/SC 1
Engineer : Vincent CHAPELAIN
International Direct line:
+33 (0)1 41 62 84 34
vincent.chapelain@afnor.fr
Secretary : Patricia DARRAS
International Direct line :
+33 (0)1 41 62 84 46
patricia.darras@afnor.fr
CEN/TC 121/SC 1 N 525
2001-10-30
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Final draft prEN ISO 15609-5
" Specification and qualification of welding
procedures for metallic materials - Welding
procedure specification - Part 5: Resistance
welding"
(ISO/FDIS 15609-5:2001)
Note of the secretariat :
This document contains the updated version of pr EN ISO 15609-5, which
has been prepared and finalized by WG 10, and the handling of the enquiry
comments.
Document type: European Standard
Document subtype:
Document stage: Parallel Formal Vote
Document language: E
C:\Program Files\Adobe\Acrobat 4.0\Acrobat\plug_ins\OpenAll\Transform\temp\EN_ISO_15609-5_(E).doc STD
Version 2.0
CEN TC 121
Date: 2001-10
prEN ISO/FDIS 15609-5:2001(E)
CEN TC 121
Secretariat: DS
Specification and qualification of welding procedures for metallic
materials Welding procedure specification Part 5: Resistance welding
(ISO/FDIS 15609-5:2001(E))
Anforderung und Qualifikation von Schweiverfahren fr metallische Werkstoffe Schweianweisung Teil 5:
Widerstandsschweien (ISO/DIS 15609-5:2001)
Descriptif et qualification d'un mode opratoire de soudage pour les matriaux mtalliques Descriptif et
qualification d'un mode opratoire de soudage Partie 5 : Soudage par rsistance (ISO/DIS 15609-5:2001)
ICS:
Descriptors:
prEN ISO/FDIS 15609-5:2001(E) (E)
2
Contents
Foreword ..................................................................................................................................................................... 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
4.4 Common to all welding procedures ............................................................................................................ 6
Annex A (informative) Welding procedure specification I Pl anned process requirements....................... 9
Annex B (informative) Welding procedure specification II Quality acceptance criteri a .......................... 11
Annex C (informative) Welding procedure specification III Wel ding machine set-up.............................. 12
Annex ZA (informative) Clauses of this European Standard addressing essenti al requirements or other
provisions of EU Directives ....................................................................................................................... 13
Bibliography ............................................................................................................................................................. 14
prEN ISO/FDIS 15609-5:2001(E) (E)
3
Foreword
This document has been prepared by CEN /TC 121, "Welding" in collaboration with ISO/TC 44 "Welding and allied
processes".
This document is currently submitted to the Parallel Formal Vote.
This document has been prepared under a mandate given to CEN by the European Commission and the European
Free Trade Association, and supports essential requirements of EU Directive(s).
For relationship with EU Directive(s), see informative annex Z, which is an integral part of this document.
prEN ISO/FDIS 15609-5:2001(E) (E)
4
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.
prEN ISO/FDIS 15609-5:2001(E) (E)
5
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 prEN ISO 15607, 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
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).
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).
EN ISO 4063, Welding and allied processes Nomenclature of processes and reference numbers
(ISO 4063: 1998).
EN ISO 5183-1, Resistance spot welding Electrode adaptors, male taper 1:10 Part 1: Conical fixing, taper
1:10 (ISO 5183-1: 1998).
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: 1993).
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: 1993).
prEN 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).
prEN ISO 14327, Resistance welding Procedures for determining the weldability lobe for resistance spot,
projection and seam welding (ISO/FDIS 14327: 2001).
prEN ISO 15607, Specification and approval of welding procedures for metallic materials General rules
(ISO/DIS 15607: 2000).
ISO 669, Electric resistance welding Resistance welding equipment Mechanical and electrical requirements.
prEN ISO/FDIS 15609-5:2001(E) (E)
6
3 Terms and definitions
For the purposes of this European Standard, the terms and definitions given in prEN ISO 15607 and ISO 669
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 4.5.
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 materi al
Designation of the materials, preferably by reference to an appropriate standard;
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):
manual:
machine;
gun.
prEN ISO/FDIS 15609-5:2001(E) (E)
7
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 according to 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
The following shall be specified when applicable:
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.
prEN ISO/FDIS 15609-5:2001(E) (E)
8
4.4.5 Welding technique
The following shall be specified when applicable:
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
The following shall be specified when applicable:
shape, dimensions and material composition of electrodes, see EN 25184, caps see EN 25821, adaptors see
EN ISO 5183-1 and prEN 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
The following shall be specified when applicable:
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;
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 prEN ISO 14327.
prEN ISO/FDIS 15609-5:2001(E) (E)
9
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 category:
Assembly name: Product identification No.
1)
:
Assembly No.
1)
: J oint location/operation
Number/identification code
1)
: J oint type:
Parent material: Form:
Surface condition: Weld pattern/sequence (sketch)
1)
:
Number of welds per joint: Quality acceptance specification: Annex B
Procedure specifi cation
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:

1) Insert drawing number
prEN ISO/FDIS 15609-5:2001(E) (E)
10
* 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:
prEN ISO/FDIS 15609-5:2001(E) (E)
11
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)
:
J oint type: J oint location/operation
number/identification code
1)
:
Quality requi rements
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:

1) Insert drawing number
prEN ISO/FDIS 15609-5:2001(E) (E)
12
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)
:
J oint type: J oint 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:

1) Insert drawing number
prEN ISO/FDIS 15609-5:2001(E) (E)
Annex ZA
(informative)
Clauses of this European Standard addressing essential requirements or
other provisions of EU Directives
This European standard has been prepared under a mandate given to CEN by the European Commission and the
European Free Trade Association and supports essential requirements of EU Directive 97/23/EEC.
WARNING : Other requirements and other EU Directives may be applicable to the product(s) falling within the
scope of this standard.
The following clauses of this standard are likely to support requirements of Directive 97/23/EEC.
Compliance with the clauses of this standard provides one means of conforming with the specific essential
requirements of the Directive concerned and associated EFTA regulations.
Table ZA.1 Relation between this European standard and the Di rective 97/23/EEC
Clauses/Paragraphs of this European
standard
Essential requirement of the Directive
97/23/EEC
Comments/Notes
All clauses Annex I, 3.1.2 Permanent joining
prEN ISO/FDIS 15609-5:2001(E) (E)
14
Bibliography
List of ISO standards conforming to European standards quoted in cl ause 2
European standard given
in clause 2
ISO standard
corresponding
Title of the ISO standard
EN 25184 ISO 5184: 1979 Straight resistance spot welding electrodes
EN 25821 ISO 5821: 1979 Resistance spot welding, electrode caps
EN 25827 ISO 5827: 1983 Spot welding Electrode back-ups and clamps
EN 28430-1 ISO 8430-1: 1988 Resistance spot welding Electrode holders Part 1: Taper
fixing 1:10
EN 28430-2 ISO 8430-2: 1988 Resistance spot welding Electrode holders
Part 2: Morse taper fixing
EN 28430-3 ISO 8430-3: 1988 Resistance spot welding Electrode holders
Part 3: Parallel shank fixing for end thrust