DIN EN ISO 18595-2007 Resistance welding - Spot welding of aluminium and aluminium alloys - Weldability welding and testing (ISO 18595 2007) English version of DIN EN ISO 18595 200.pdf

1、December 2007DEUTSCHE NORM English price group 12No part of this standard may be reproduced without prior permission ofDIN Deutsches Institut fr Normung e. V., Berlin. Beuth Verlag GmbH, 10772 Berlin, Germany,has the exclusive right of sale for German Standards (DIN-Normen).ICS 25.160.10!$JH“1398837

2、www.din.deDDIN EN ISO 18595Resistance welding Spot welding of aluminium and aluminium alloys Weldability, welding and testing (ISO 18595:2007)English version of DIN EN ISO 18595:2007-12Widerstandsschweien Punktschweien von Aluminium und Aluminiumlegierungen Schweieignung, Schweien und Prfungen (ISO

3、18595:2007)Englische Fassung DIN EN ISO 18595:2007-12www.beuth.deDocument comprises 26 pagesDIN EN ISO 18595:2007-12 2 National foreword This standard has been prepared by Technical Committee ISO/TC 44 “Welding and allied processes” in collaboration with Technical Committee CEN/TC 121 “Welding” (Sec

4、retariat: DIN, Germany). The responsible German body involved in its preparation was the Normenausschuss Schweitechnik (Welding Standards Committee), Joint Committee NA 092-00-12 AA Widerstandsschweien (DVS AG V 3). The DIN Standards corresponding to the International Standards referred to in the EN

5、 are as follows: ISO 669:2000 DIN ISO 669:2001-06 ISO 5182 DIN ISO 5182 ISO 5184 DIN ISO 5184 ISO 5821 DIN ISO 5821 ISO 10447 DIN EN ISO 10447 ISO 14329:2003 DIN EN ISO 14329:2003-12 ISO 14373 DIN EN ISO 14373 ISO 15614-12 DIN EN ISO 15614-12 National Annex NA (informative) Bibliography DIN ISO 669:

6、2000, Resistance welding Resistance welding equipment Mechanical and electrical requirements (ISO 669:2000) DIN ISO 5182, Welding Materials for resistance welding electrodes and ancillary equipment DIN ISO 5184, Straight resistance spot welding electrodes DIN ISO 5821, Resistance spot welding electr

7、ode caps DIN EN ISO 10447, Resistance welding Peel and chisel testing of resistance spot and projection welds DIN EN ISO 14329:2003-12, Resistance welding Destructive tests of welds Failure types and geometric measurements for resistance spot, seam and projection welds (ISO 14329:2003) DIN EN ISO 14

8、373, Resistance welding Procedure for spot welding of uncoated and coated low carbon steels DIN EN ISO 15614-12, Specification and qualification of welding procedures for metallic materials Welding procedure test Part 12: Spot, seam and projection welding EUROPEAN STANDARDNORME EUROPENNEEUROPISCHE N

9、ORMEN ISO 18595September 2007ICS 25.160.10English VersionResistance welding - Spot welding of aluminium and aluminiumalloys - Weldability, welding and testing (ISO 18595:2007)Soudage par rsistance - Soudage par points delaluminium et des alliages daluminium - Soudabilit,soudage et essais (ISO 18595:

10、2007)Widerstandsschweien - Punktschweien von Aluminiumund Aluminiumlegierungen - Schweieignung, Schweienund Prfungen (ISO 18595:2007)This European Standard was approved by CEN on 8 August 2007.CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions fo

11、r giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such nationalstandards may be obtained on application to the CEN Management Centre or to any CEN member.This European Standard exists in three official

12、versions (English, French, German). A version in any other language made by translationunder the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as theofficial versions.CEN members are the national standards bodies of Austria, Belgiu

13、m, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland,France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal,Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.EUROPEAN COMMITTEE FOR STAN

14、DARDIZATIONCOMIT EUROPEN DE NORMALISATIONEUROPISCHES KOMITEE FR NORMUNGManagement Centre: rue de Stassart, 36 B-1050 Brussels 2007 CEN All rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN ISO 18595:2007: EContents Page 2 EN ISO 18595:2007 (E)

15、 Foreword .3 1 Scope .4 2 Normative references .4 3 Terms and definitions 5 4 Symbols .8 5 Material 9 5.1 Form .9 5.2 Types of aluminium alloys .9 6 Surface conditions .9 7 Edge distance, edge conditions, form of component and weld spacing .9 8 Electrodes . 10 8.1 Materials . 10 8.2 Dimensions . 10

16、8.3 Cooling electrodes 12 9 Weld assessment . 12 9.1 General 12 9.2 Weldability test procedure 12 9.3 Procedure qualification tests . 13 9.4 Production tests 14 9.5 Frequency of testing . 14 10 Weld quality requirements 14 10.1 Weld diameter 14 10.2 Weld dimensions . 15 10.3 Weld fracture mode . 15

17、10.4 Weld strength . 15 10.5 Weld appearance Surface condition . 15 11 Multi-weld arrays . 16 Annex A (informative) Recommendations for spot welding equipment . 18 Annex B (informative) Typical spot welding conditions . 19 Annex C (informative) Non-exhaustive list of aluminium alloys covered by this

18、 International Standard . 20 Annex D (informative) Typical information to appear on a welding procedure sheet for spot welding 22 Bibliography 24 Foreword allied processes“ in collaboration with Technical Committee CEN/TC 121 “Welding“, the secretariat of which is held by DIN. This European Standard

19、 shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by March 2008, and conflicting national standards shall be withdrawn at the latest by March 2008. According to the CEN/CENELEC Internal Regulations, the national standards o

20、rganizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal

21、, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and the United Kingdom. Endorsement notice The text of ISO 18595:2007 has been approved by CEN as a EN ISO 18595:2007 without any modification. 3 This document (EN ISO 18595:2007) has been prepared by Technical Committee ISO/TC 44 “Welding an

22、d EN ISO 18595:2007 (E) 1 Scope This International Standard specifies requirements for resistance spot welding in the fabrication of assemblies of aluminium sheet, extrusions (both work- and age-hardening alloys) and/or cast material comprising two or three thicknesses of metal, where the maximum si

23、ngle (sheet) thickness of components to be welded is within the range 0,6 mm to 6 mm. This International Standard is applicable to the welding of sheets or plates of dissimilar thickness where the thickness ratio is less than or equal to 3:1. It applies to the welding of three thicknesses where the

24、total thickness is less than or equal to 9 mm. Welding with the following types of machines is within the scope of this International Standard: pedestal welding machines; gun welders; automatic welding equipment where the components are fed by robots or automatic feeding equipment; multi-welders; ro

25、botic welders. Information on appropriate welding equipment is given in Annex A and on spot welding conditions in Annex B. The latter are for guidance only and may require modification depending on service conditions of the fabrication, type of welding equipment, characteristics of the secondary cir

26、cuit, electrode material and geometry. The welding of coated material, e.g. zinc-coated or anodised material, is not within the scope of this International Standard. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references

27、, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. ISO 669:2000, Resistance welding Resistance welding equipment Mechanical and electrical requirements ISO 5182, Welding Materials for resistance welding electrod

28、es and ancillary equipment ISO 5184, Straight resistance spot welding electrodes ISO 5821, Resistance spot welding electrode caps 4 EN ISO 18595:2007 (E) ISO 5830, Resistance spot welding Male electrode caps ISO 10447, Resistance welding Peel and chisel testing of resistance spot and projection weld

29、s ISO 14329:2003, Resistance welding Destructive tests of welds Failure types and geometric measurements for resistance spot, seam, and projection welds ISO 15614-12, Specification and qualification of welding procedures for metallic materials Welding procedure test Part 12: Spot, seam and projectio

30、n welding 3 Terms and definitions For the purposes of this document, the terms and definitions given in ISO 669:2000 and ISO 14329:2003 and the following apply. 3.1 corona bond zone zone outside the weld nugget in which solid phase bonding has occurred NOTE 1 See Figure 1. NOTE 2 This zone can contr

31、ibute towards the strength of the joints but may not be considered for design purposes. 3.2 corona bond diameter dcouter diameter of the corona bond zone NOTE See Figure 1. 3.3 cross-tension test test to determine the load-carrying behaviour of a spot-welded joint subjected to cross-tension loading

32、3.4 interface failure fracture through the weld nugget between the sheets in the plane of the interface NOTE See Figure 1. 3.5 nugget diameter dnmean of the maximum and minimum diameters of the fused nugget in the plane of the interface between the pieces joined, measured on a metallographic section

33、 taken transversely through the centre of the nugget NOTE See Figure 1. The nugget diameter is the parameter on which the mechanical behaviour of a structure is based. Other parameters such as the plug or weld diameter can be influenced by the type of destructive test. 3.6 plug failure slug/button f

34、ailure fracture in the base metal, the heat-affected zone, or the nugget leaving attached metal pulled through thickness from the opposing sheet NOTE See Figure 2. 5 EN ISO 18595:2007 (E) 3.7 partial plug failure fracture partly in the base material or the heat-affected zone and partly in the nugget

35、 leaving attached metal pulled through thickness from the opposing sheet NOTE See Figure 2. 3.8 shear test tensile shear test test to determine the load-carrying behaviour of a spot-welded joint subjected to shear tension loading 3.9 weld diameter d in an interface failure mean diameter of the fused

36、 zone measured at the interface omitting the corona bond 3.10 weld diameter d in a plug failure mean diameter of the plug NOTE See Figure 2 a) and b). 3.11 weld diameter d in a partial plug failure mean diameter of the fused zone measured at the interface, omitting the corona bond area and the maxim

37、um diameter of the plug component of the failure NOTE 1 See Figure 2 c). NOTE 2 The minimum diameter of the plug component of the fracture is reported separately (see Figures 1 and 2). NOTE 3 The plug diameter in aluminium spot welds is generally less than or equal to the diameter of the (weld) nugg

38、et. 3.12 weld nugget lenticular zone in a resistance weld where metal from both (all) sheets has melted and resolidified 3.13 plug diameter dpmean diameter of the plug in both plug and partial plug failure modes NOTE See Figure 2. 6 EN ISO 18595:2007 (E) Key 1 weld with interfacial fracture (d dn) a

39、Corona bond diameter. 2 corona bond zone bNugget diameter. 3 molten material of the nugget cWeld diameter (d1or d2). 4 rough fracture zone Figure 1 Measurement of weld size Weld with interface failure a) Symmetrical plug failureab) Asymmetrical plug failurea7 EN ISO 18595:2007 (E) c) Partial plug fa

40、ilurebad = dp= (d1+ d2)/2 bd = (d1+ d2)/2 and dp= (d2+ d3)/2 Figure 2 Measurement of weld size Weld with plug (slug) failure 4 Symbols Symbol Term Unit d weld diameter mm dccorona bond diameter mm diinitial or set-up weld diameter mm dnnugget diameter mm dpplug diameter mm dtinitial electrode tip di

41、ameter mm t sheet thickness mm Psshear strength of weld kN Rmultimate strength of aluminium being welded MPa 8 EN ISO 18595:2007 (E) 5 Material 5.1 Form The material shall be flat rolled, extruded or cast and shall be free from harmful imperfections. 5.2 Types of aluminium alloys A partial list of a

42、luminium alloys is given in Annex C. 6 Surface conditions Prior to welding, all surfaces shall be checked for their suitability for spot welding. The surfaces should be free from oil, grease, lubricant, visible oxidation, paint, dirt, or excessive scratches. If necessary, appropriate surface treatme

43、nt, e.g. chemical etching, shall be carried out. Mill-finish surfaces are generally not suitable for spot welding; however, aluminium manufacturers can supply surface-treated material suitable for spot welding, e.g. with TiZr conversion coating. Extrusions shall also be in the mill-finish condition

44、and will generally require pre-treatment. Die-cast material shall be free from excessive surface roughness and imperfections, e.g. as caused by washing out of the die material. Excessive quantities of dissolved gases in die-cast material shall be avoided. In addition, coated material can be supplied

45、 with chromate or phosphate passivation. Phosphated aluminium may be used in certain applications. These materials can be spot welded, although adjustment to the welding parameters will generally be necessary as outlined in Annex B. NOTE In most countries, chromate passivation treatment will be proh

46、ibited in the near future to avoid health risks. 7 Edge distance, edge conditions, form of component and weld spacing The components to be welded shall be free from burrs or other defects, which may, in any way, interfere with interface contact or require excessive force to fit the parts together. T

47、he shape of the component shall be such that there is satisfactory interfacial contact in the area where welds are to be made. The distance from the edge of the component to the centre of the weld (edge distance) shall be not less than 1,25d (see Figure 3), where d is the initial weld diameter as de

48、fined in 8.2. The use of edge distances lower than the recommended values will adversely influence weld quality. Edge distances lower than the recommended values should be used only when expressly specified. In this case the nominal weld size specified may be less than that given in 8.2, and therefo

49、re due allowance needs to be made for a lower weld strength (see 10.4). The weld pitch, i.e. the centre-to-centre distance between adjacent spot welds (see Figure 3), shall not be less than 6d and preferably larger. Tolerances for distances between the centres of two adjacent spot welds should not exceed 10 % provided that the pitch does not fall below the minimum value. Smaller weld pitches may be specified provided that the current is increased after the first weld to compensate for th