SIST EN ISO 18595:2021
(Main)Resistance welding - Spot welding of aluminium and aluminium alloys - Weldability, welding and testing (ISO 18595:2021)
Resistance welding - Spot welding of aluminium and aluminium alloys - Weldability, welding and testing (ISO 18595:2021)
This document 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 single (sheet) thickness of components to be
welded is within the range 0,6 mm to 6 mm.
This document 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 total
thickness is less than or equal to 9 mm.
Welding with the following types of machines is within the scope of this document:
— pedestal welding machines;
— gun welders;
— automatic welding equipment where the components are fed by robots or automatic feeding
equipment;
— multi-welders;
— robotic 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 can require modification depending on service conditions
of the fabrication, type of welding equipment, characteristics of the secondary circuit, electrode
material and geometry.
The welding of coated material, e.g. zinc-coated or anodized material, is outside the scope of this
document.
Widerstandsschweißen - Punktschweißen von Aluminium und Aluminiumlegierungen - Schweißeignung, Schweißen und Prüfungen (ISO 18595:2021)
Dieses Dokument legt Anforderungen für das Widerstandspunktschweißen bei der Herstellung von Verbindungen aus Aluminiumblech, Strangpressprofilen (kaltverfestigte und ausgehärtete Legierungen) und/oder Gusswerkstoffen im Zwei- oder Dreilagen-Punktschweißen fest. Dabei liegt die maximale Einzelblechdicke der zu schweißenden Bauteile in einem Bereich von 0,6 mm bis 6 mm.
Dieses Dokument ist für das Schweißen von Blechen oder Platten verschiedener Dicken, wobei das Dickenverhältnis kleiner oder gleich 3:1 ist, anzuwenden. Es ist für das Dreilagenschweißen bis zu einer Gesamtdicke von 9 mm anzuwenden.
Schweißen mit den folgenden Maschinenarten fällt in den Anwendungsbereich dieses Dokuments:
— Ständerschweißanlagen;
— Punktschweißgeräte mit Stoßelektrode;
— Automatik-Schweißeinrichtungen, bei denen die Bauteile von Robotern oder automatischen Vorschubeinrichtungen zugeführt werden;
— Vielpunktschweißanlagen;
— Schweißroboter.
Angaben über geeignete Schweißeinrichtungen sind in Anhang A enthalten und über Punktschweiß-bedingungen in Anhang B. Letztere dienen nur zur Information und können Änderungen erforderlich machen, abhängig von den Betriebsbedingungen bei der Herstellung, der Art der Schweißeinrichtung, den Kenndaten des Sekundärstromkreises, dem Elektrodenwerkstoff und der Geometrie.
Schweißen von beschichtetem Werkstoff, z. B. Werkstoffe mit Zinküberzug oder anodisierte Werkstoffe, liegt außerhalb des Anwendungsbereiches dieses Dokuments.
Soudage par résistance - Soudage par points de l'aluminium et des alliages d'aluminium - Soudabilité, soudage et essais (ISO 18595:2021)
Le présent document spécifie les exigences relatives au soudage par résistance par points réalisé pour la fabrication d'assemblages de tôles d'aluminium, de pièces extrudées (alliages écrouis et vieillis) et/ou de pièces moulées comprenant deux ou trois épaisseurs de métal, dont l'épaisseur (de tôle) unique maximale des composants à souder est comprise entre 0,6 mm et 6 mm.
Le présent document s'applique au soudage de tôles ou de plaques d'épaisseurs différentes et dont le rapport entre les épaisseurs est inférieur ou égal à 3:1. Il s'applique au soudage de trois épaisseurs dont l'épaisseur totale est inférieure ou égale à 9 mm.
Le soudage avec les types de machines ci-dessous entre dans le domaine d'application du présent document:
— machines de soudage avec commande au pied;
— pinces à souder;
— matériel de soudage automatique avec lequel les composants sont mis en place par des robots ou par des appareils d'alimentation automatique;
— machines à souder multipoints;
— robots de soudage.
Les informations sur le matériel de soudage adéquat sont fournies à l'Annexe A et les informations sur les conditions de soudage par points sont fournies à l'Annexe B. Ces dernières sont communiquées à titre informatif uniquement et peuvent impliquer des modifications selon les conditions de fabrication, le type de matériel de soudage, les caractéristiques du circuit secondaire et du matériau et la forme de l'électrode.
Le soudage de matériaux revêtus (les matériaux galvanisés ou anodisés, par exemple) n'entre pas dans le domaine d'application du présent document.
Uporovno varjenje - Točkovno varjenje aluminija in aluminijevih zlitin - Varivost, varjenje in preskušanje (ISO 18595:2021)
General Information
Relations
Standards Content (Sample)
SLOVENSKI STANDARD
SIST EN ISO 18595:2021
01-maj-2021
Nadomešča:
SIST EN ISO 18595:2008
Uporovno varjenje - Točkovno varjenje aluminija in aluminijevih zlitin - Varivost,
varjenje in preskušanje (ISO 18595:2021)
Resistance welding - Spot welding of aluminium and aluminium alloys - Weldability,
welding and testing (ISO 18595:2021)
Widerstandsschweißen - Punktschweißen von Aluminium und Aluminiumlegierungen -
Schweißeignung, Schweißen und Prüfungen (ISO 18595:2021)
Soudage par résistance - Soudage par points de l'aluminium et des alliages d'aluminium
- Soudabilité, soudage et essais (ISO 18595:2021)
Ta slovenski standard je istoveten z: EN ISO 18595:2021
ICS:
25.160.10 Varilni postopki in varjenje Welding processes
77.120.10 Aluminij in aluminijeve zlitine Aluminium and aluminium
alloys
SIST EN ISO 18595:2021 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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SIST EN ISO 18595:2021
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SIST EN ISO 18595:2021
EN ISO 18595
EUROPEAN STANDARD
NORME EUROPÉENNE
February 2021
EUROPÄISCHE NORM
ICS 25.160.10 Supersedes EN ISO 18595:2007
English Version
Resistance welding - Spot welding of aluminium and
aluminium alloys - Weldability, welding and testing (ISO
18595:2021)
Soudage par résistance - Soudage par points de Widerstandsschweißen - Punktschweißen von
l'aluminium et des alliages d'aluminium - Soudabilité, Aluminium und Aluminiumlegierungen -
soudage et essais (ISO 18595:2021) Schweißeignung, Schweißen und Prüfungen (ISO
18595:2021)
This European Standard was approved by CEN on 30 January 2021.
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 CEN-CENELEC Management Centre 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 CEN-CENELEC Management
Centre has the same status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,
Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and
United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2021 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN ISO 18595:2021 E
worldwide for CEN national Members.
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SIST EN ISO 18595:2021
EN ISO 18595:2021 (E)
Contents Page
European foreword . 3
2
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SIST EN ISO 18595:2021
EN ISO 18595:2021 (E)
European foreword
This document (EN ISO 18595:2021) has been prepared by Technical Committee ISO/TC 44 "Welding
and allied processes" in collaboration with Technical Committee CEN/TC 121 “Welding and allied
processes” the secretariat of which is held by DIN.
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 August 2021, and conflicting national standards shall
be withdrawn at the latest by August 2021.
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. CEN shall not be held responsible for identifying any or all such patent rights.
This document supersedes EN ISO 18595:2007.
According to the CEN-CENELEC Internal Regulations, the national standards organizations of the
following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria,
Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland,
Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Republic of
North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the
United Kingdom.
Endorsement notice
The text of ISO 18595:2021 has been approved by CEN as EN ISO 18595:2021 without any modification.
3
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SIST EN ISO 18595:2021
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SIST EN ISO 18595:2021
INTERNATIONAL ISO
STANDARD 18595
Second edition
2021-01
Resistance welding — Spot welding of
aluminium and aluminium alloys —
Weldability, welding and testing
Soudage par résistance — Soudage par points de l'aluminium et des
alliages d'aluminium — Soudabilité, soudage et essais
Reference number
ISO 18595:2021(E)
©
ISO 2021
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SIST EN ISO 18595:2021
ISO 18595:2021(E)
COPYRIGHT PROTECTED DOCUMENT
© ISO 2021
All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may
be reproduced or utilized otherwise in any form or by any means, electronic or mechanical, including photocopying, or posting
on the internet or an intranet, without prior written permission. Permission can be requested from either ISO at the address
below or ISO’s member body in the country of the requester.
ISO copyright office
CP 401 • Ch. de Blandonnet 8
CH-1214 Vernier, Geneva
Phone: +41 22 749 01 11
Email: copyright@iso.org
Website: www.iso.org
Published in Switzerland
ii © ISO 2021 – All rights reserved
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SIST EN ISO 18595:2021
ISO 18595:2021(E)
Contents Page
Foreword .iv
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 2
4 Material . 2
4.1 Form . 2
4.2 Types of aluminium alloys . 2
5 Surface conditions . 2
6 Edge distance, edge conditions, form of component and weld spacing .2
7 Electrodes . 3
7.1 Materials . 3
7.2 Dimensions . 3
7.3 Cooling electrodes . 4
8 Qualification of welds . 4
8.1 General . 4
8.2 Weldability test . 4
8.3 Pre-production tests . 4
8.4 Routine tests . 4
8.4.1 Type of tests . 4
8.4.2 Frequency of testing . 4
9 Weld quality requirements . 5
9.1 Weld diameter . 5
9.2 Weld dimensions . 5
9.3 Weld fracture mode . 5
9.4 Weld strength . 5
9.5 Weld appearance — Surface condition . 7
10 Multi-weld arrays . 8
Annex A (informative) Typical spot welding conditions .10
Annex B (informative) Non-exhaustive list of aluminium alloys covered by this document.11
Annex C (informative) Typical information to appear on a welding procedure sheet for spot
welding .13
Bibliography .15
© ISO 2021 – All rights reserved iii
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SIST EN ISO 18595:2021
ISO 18595:2021(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 out
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.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www .iso .org/ directives).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www .iso .org/ patents).
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and
expressions related to conformity assessment, as well as information about ISO's adherence to the
World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT), see www .iso .org/
iso/ foreword .html.
This document was prepared by Technical Committee ISO/TC 44, Welding and allied processes,
Subcommittee SC 6, Resistance welding and allied mechanical joining, in collaboration with the European
Committee for Standardization (CEN) Technical Committee CEN/TC 121, Welding and allied processes,
in accordance with the Agreement on technical cooperation between ISO and CEN (Vienna Agreement).
This second edition cancels and replaces the first edition (ISO 18595:2007), which has been technically
revised.
The main changes compared to the previous edition are as follows:
— new Clause 3 Terms and definitions has been added;
— the whole document has been technically revised to the state of the art;
— Annex C has been revised.
Any feedback or questions on this document should be directed to the user’s national standards body. A
complete listing of these bodies can be found at www .iso .org/ members .html.
Official interpretations of ISO/TC 44 documents, where they exist, are available from this page: https://
committee .iso .org/ sites/ tc44/ home/ interpretation .html.
iv © ISO 2021 – All rights reserved
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SIST EN ISO 18595:2021
INTERNATIONAL STANDARD ISO 18595:2021(E)
Resistance welding — Spot welding of aluminium and
aluminium alloys — Weldability, welding and testing
1 Scope
This document 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 single (sheet) thickness of components to be
welded is within the range 0,6 mm to 6 mm.
This document 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 total
thickness is less than or equal to 9 mm.
Welding with the following types of machines is within the scope of this document:
— pedestal welding machines;
— gun welders;
— automatic welding equipment where the components are fed by robots or automatic feeding
equipment;
— multi-welders;
— robotic 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 can require modification depending on service conditions
of the fabrication, type of welding equipment, characteristics of the secondary circuit, electrode
material and geometry.
The welding of coated material, e.g. zinc-coated or anodized material, is outside the scope of this
document.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements 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.
ISO 209, Aluminium and aluminium alloys — Chemical composition
ISO 669, Resistance welding — Resistance welding equipment — Mechanical and electrical requirements
ISO 3522, Aluminium and aluminium alloys — Castings — Chemical composition and mechanical properties
ISO 5182, Resistance welding — Materials for electrodes and ancillary equipment
ISO 5184, Straight resistance spot welding electrodes
ISO 5821, Resistance welding — Spot welding electrode caps
ISO 5830, Resistance spot welding — Male electrode caps
ISO 10447, Resistance welding — Testing of welds — Peel and chisel testing of resistance spot and
projection welds
© ISO 2021 – All rights reserved 1
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SIST EN ISO 18595:2021
ISO 18595:2021(E)
ISO 14273, Resistance welding — Destructive testing of welds — Specimen dimensions and procedure for
tensile shear testing resistance spot and embossed projection welds
ISO 15614-12, Specification and qualification of welding procedures for metallic materials — Welding
procedure test — Part 12: Spot, seam and projection welding
ISO 17677-1, Resistance welding — Vocabulary — Part 1: Spot, projection and seam welding
ISO 18278-2, Resistance welding — Weldability — Part 2: Evaluation procedures for weldability in
spot welding
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 669 and ISO 17677-1 apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https:// www .iso .org/ obp
— IEC Electropedia: available at http:// www .electropedia .org/
4 Material
4.1 Form
The material shall be according to ISO 209 and ISO 3522.
4.2 Types of aluminium alloys
A partial list of aluminium alloys is given in Annex C.
5 Surface conditions
Prior to welding, all surfaces shall be checked for their suitability for spot welding. The surfaces should
preferably be free from oil, grease, lubricant, visible oxidation, paint, dirt or excessive scratches. If
necessary, appropriate surface treatment, e.g. chemical etching, shall be carried out. Unless specifically
developed for spot welding, mill-finish surfaces are generally not suitable for spot welding and can need
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. Aluminium manufacturers and component suppliers
can produce surface-treated material suitable for spot welding, e.g. with TiZr conversion coating.
In addition, coated material can be supplied with chromate or phosphate passivation. Phosphated
aluminium may be used in certain applications. Excessive quantities of dissolved gases in die-cast
material shall be avoided. These materials can be spot welded, although adjustment of the welding
parameters is generally necessary as outlined in Annex B.
In all cases, the surface condition and any surface treatment shall be recorded in the testing
documentation.
The stability of surface condition can be evaluated by measuring the transition resistance in accordance
with ISO 18594.
6 Edge distance, edge conditions, form of component and weld spacing
The components to be welded shall be free from burrs or other defects, which can, in any way, interfere
with interface contact or require excessive force to fit the parts together.
2 © ISO 2021 – All rights reserved
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SIST EN ISO 18595:2021
ISO 18595:2021(E)
The 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 1,25 d (see Figure 2), where d is the target weld diameter as defined in
8.2. The use of edge distances smaller than the recommended values adversely influence weld quality.
Edge distances smaller than the recommended values should be used only when expressly specified.
In this case, the nominal weld diameter specified may be less than that given in 8.2, and therefore due
allowance needs to be made for a lower weld strength (see 9.4).
7 Electrodes
7.1 Materials
The electrode materials shall be copper alloy and should possess high thermal and electrical
conductivity. The electrode materials shall comply, and be used in accordance, with ISO 5182. If other
electrode materials are used, then these shall be recorded in the testing documentation.
7.2 Dimensions
The welding electrodes shall be of sufficient cross-sectional area and strength to carry the welding
current and electrode force without overheating, excessive deformation, or excessive deflection. If
possible, electrodes with a minimum shank diameter, D, of 20 mm should be used. If other electrode
diameters are used, then these shall be recorded in the testing documentation.
The electrode dimensions shall, where practicable, conform to ISO 5184 for straight electrodes,
ISO 5821 for female electrode caps, or ISO 5830 for male electrode caps, as applicable. In cases where
these standards do not apply, the dimensions of the electrode shall be specified such that welds
conforming to this document are produced.
It is recommended to employ either radiused electrodes or electrodes with a tip diameter greater than
the target weld diameter d.
When welding two sheets of dissimilar thickness, the electrode dimensions and the required weld
diameter should be specified with reference to the thickness of the thinner sheet. In the case of three
thicknesses, the thinner sheet of each combination should be used as the reference.
The electrode tip geometry and target weld diameter requirement shall be recorded in the testing
documentation.
During normal production, electrodes tend to wear, leading to an increase in electrode tip diameter and
damage to the tip surface geometry. The condition of at least one of the electrodes should not be allowed
to deteriorate to a level that results in a reduction in weld diameter to less than the acceptable minimum,
e.g. 4 t . When this diameter has been reached (if not earlier), the electrode shall be replaced or
restored to its initial diameter and geometry, e.g. by electrode tip dressing.
A common method to control process deterioration is to measure the increase in electrode tip geometry
(or contact rea on the sheet surface), where electrode tips of different diameters are in contact with the
piece to be welded, the permissible increase over the initial diameter shall apply to the smaller of the
two electrode tips.
A greater increase in the diameter of the electrode(s) is permissible only if tests prove that the strength
of the weld does not fall below the desired requirements, and only by specification.
In cases where adaptive control or automatic weld current increase (i.e. stepper controls), or other
forms of process control are used, a greater deterioration in electrode tip condition can be tolerated.
The acceptable increase in tip diameter can be determined by empirical means provided that the weld
diameter does not fall below target weld diameter unless otherwise specified.
© ISO 2021 – All rights reserved 3
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SIST EN ISO 18595:2021
ISO 18595:2021(E)
7.3 Cooling electrodes
The water flow rate should be a minimum of 6 l/min per electrode for welding two thicknesses up to
and including 3 mm. Higher flow rates can be beneficial for extending electrode life. The internal water-
cooling feed tube should be adjusted to ensure that the water impinges on the backward working face
of the electrode. The distance between the back face and the working face of the electrode should not
exceed the values given in the relevant International Standard. To achieve satisfactory electrode life,
the inlet water temperature of cooling liquid should not exceed 30 °C (303 K).
8 Qualification of welds
8.1 General
A procedure shall be established for each welding machine, sheet thickness and material, or
combinations thereof, used in the component being welded. The record of the procedures should be
based on the appropriate items from the list given in Annex C.
8.2 Weldability test
The weldability test shall be according ISO 18278-2. The upper current limit, I , may be optionally
max
defined by the onset of weld splash or by a specific value (or percentage) of electrode indentation. The
method selected shall be recorded in the testing documentation.
Guidelines for welding conditions are given in Annex A and Annex B.
8.3 Pre-production tests
Pre-production tests shall be carried out in accordance with ISO 15614-12.
8.4 Routine tests
8.4.1 Type of tests
The following tests shall be carried out to ensure consistent spot-weld quality under production
conditions:
a) visual examination;
b) either a peel or chisel test (manual or mechanized) in accordance with ISO 10447.
In addition, other tests, such as tensile shear tests, may be carried out.
8.4.2 Frequency of testing
When practicable, actual components shall be used for tests. When it is not practicable to use actual
components, test pieces from identical material with relevant flange widths shall be used.
When practicable, tests should be carried out on each of the following occasions:
a) at the beginning of each shift or daily work period;
b) immediately after new or reconditioned electrodes are fitted to the machine;
c) whenever any changes are made to the equipment or to its settings;
d) immediately upon change of any component of the equipment or material supply source or surface
treatment.
4 © ISO 2021 – All rights reserved
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SIST EN ISO 18595:2021
ISO 18595:2021(E)
Production shall not start until a satisfactory test weld has been obtained at the beginning of each
period specified above. In the event of the test piece failing at the end of the shift or work period, 2 %
may be selected from the production during the period following the previous test on that equipment,
and they shall be tested in accordance with Clause 9. In the event of any of the selected components
failing, the whole of the production during that period shall be deemed not to conform to this document.
For visual examination, no dressing, painting or other operation interfering with the examination of the
weld zone shall be carried out on the assemblies until after the weld has been examined. The surface of
the work pieces shall be at least of the same quality as the test pieces that conform to 9.5.
The number and type of tests shall be sufficient to establish the statistical significance of the data in
each case and shall be specified.
9 Weld quality requirements
9.1 Weld diameter
The target weld diameter, d, in millimetres, shall be specified between the contracting parties,
nominally it should be 5 t . Weld diameter and plug diameter shall be determined according to the
definition in ISO 17677-1.
CAUTION — The use of a smaller weld diameter will result in a lower weld strength. This needs
to be taken into account for any design calculations (see Table 1).
In cases where a smaller flange width is specified, which fails to satisfy the prescribed relationship
between weld diameter and edge distance (i.e. 1,25d), a smaller target weld diameter should be
specified and reference made to the appropriate application standard. In this case, allowance shall be
made in the design calculations for the lower strength obtained with smaller welds (see 9.3).
NOTE The available tolerances in welding conditions and machine operation are invariably lower at these
small weld diameters.
9.2 Weld dimensions
When spot welding two sheets of equal or unequal thickness, the electrode indentation in each sheet
should be less than 20 % of the individual sheet thickness. A larger indentation is permissible if agreed
between contracting parties or on the reverse side of a “non-marking weld”. Penetration of the weld
nugget in these cases is asymmetric and depends on the ratio of the sheet thicknesses being welded.
Depending on the product requirements, lower indentation values may be specified. In such cases,
...
SLOVENSKI STANDARD
oSIST prEN ISO 18595:2020
01-marec-2020
Uporovno varjenje - Točkovno varjenje aluminija in aluminijevih zlitin - Varivost,
varjenje in preskušanje (ISO/DIS 18595:2020)
Resistance welding - Spot welding of aluminium and aluminium alloys - Weldability,
welding and testing (ISO/DIS 18595:2020)
Widerstandsschweißen - Punktschweißen von Aluminium und Aluminiumlegierungen -
Schweißeignung, Schweißen und Prüfungen (ISO/DIS 18595:2020)
Soudage par résistance - Soudage par points de l'aluminium et des alliages d'aluminium
- Soudabilité, soudage et essais (ISO/DIS 18595:2020)
Ta slovenski standard je istoveten z: prEN ISO 18595
ICS:
25.160.10 Varilni postopki in varjenje Welding processes
77.120.10 Aluminij in aluminijeve zlitine Aluminium and aluminium
alloys
oSIST prEN ISO 18595:2020 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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oSIST prEN ISO 18595:2020
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oSIST prEN ISO 18595:2020
DRAFT INTERNATIONAL STANDARD
ISO/DIS 18595
ISO/TC 44/SC 6 Secretariat: DIN
Voting begins on: Voting terminates on:
2020-02-03 2020-04-27
Resistance welding — Spot welding of aluminium and
aluminium alloys — Weldability, welding and testing
Soudage par résistance — Soudage par points de l'aluminium et des alliages d'aluminium — Soudabilité,
soudage et essais
ICS: 25.160.10
THIS DOCUMENT IS A DRAFT CIRCULATED
This document is circulated as received from the committee secretariat.
FOR COMMENT AND APPROVAL. IT IS
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oSIST prEN ISO 18595:2020
ISO/DIS 18595:2020(E)
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oSIST prEN ISO 18595:2020
ISO/DIS 18595:2020(E)
Contents Page
Foreword .iv
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 2
4 Material . 2
4.1 Form . 2
4.2 Types of aluminium alloys . 2
5 Surface conditions . 2
6 Edge distance, edge conditions, form of component and weld spacing .3
7 Electrodes . 3
7.1 Materials . 3
7.2 Dimensions . 3
7.3 Cooling electrodes . 4
8 Qualification of welds . 4
8.1 General . 4
8.2 Pre-production tests . 4
8.3 Routine tests . 4
8.3.1 Type of tests . 4
8.3.2 Frequency of testing . 4
9 Weld quality requirements . 5
9.1 Weld diameter . 5
9.2 Weld dimensions . 5
9.3 Weld fracture mode . 5
9.4 Weld strength . 5
9.5 Weld appearance — Surface condition . 7
10 Multi-weld arrays . 7
Annex A (informative) Recommendations for spot welding equipment .10
Annex B (informative) Typical spot welding conditions .11
Annex C (informative) Non-exhaustive list of aluminium alloyscovered by this International
Standard .12
Annex D (informative) Typical information to appear on a welding procedure sheet for spot
welding .14
Annex E (informative) Examples of minimum strength requirements .16
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oSIST prEN ISO 18595:2020
ISO/DIS 18595:2020(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 out
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.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www .iso .org/ directives).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www .iso .org/ patents).
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation on the voluntary nature of standards, the meaning of ISO specific terms and
expressions related to conformity assessment, as well as information about ISO's adherence to the
World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT) see the following
URL: www .iso .org/ iso/ foreword .html.
This document was prepared by Technical Committee ISO/TC 44, Welding and allied processes,
Subcommittee SC 6, Resistance welding and allied mechanical joining.
This second edition cancels and replaces the first edition (ISO 18595:2007), which has been technically
revised.
The main changes compared to the previous edition are as follows:
— updating of chapter 3 “terms and definitions”;
— technically revised to the state of the art;
— inclusion of an informative Annex E “Examples of minimum strength requirements”.
Any feedback or questions on this document should be directed to the user’s national standards body. A
complete listing of these bodies can be found at www .iso .org/ members .html.
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oSIST prEN ISO 18595:2020
DRAFT INTERNATIONAL STANDARD ISO/DIS 18595:2020(E)
Resistance welding — Spot welding of aluminium and
aluminium alloys — Weldability, welding and testing
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 single (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 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;
— robotic 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 circuit, 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 documents are referred to in the text in such a way that some or all of their content
constitutes requirements 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.
ISO 209, Aluminium and aluminium alloys — Chemical composition
ISO 669, Resistance welding — Resistance welding equipment — Mechanical and electrical requirements
ISO 3522, Aluminium and aluminium alloys — Castings — Chemical composition and mechanical properties
ISO 5182, Resistance welding — Materials for electrodes and ancillary equipment
ISO 5184, Straight resistance spot welding electrodes
ISO 5821, Resistance welding — Spot welding electrode caps
ISO 5830, Resistance spot welding — Male electrode caps
ISO 10447, Resistance welding — Testing of welds — Peel and chisel testing of resistance spot and
projection welds
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oSIST prEN ISO 18595:2020
ISO/DIS 18595:2020(E)
ISO 14273, Resistance welding — Destructive testing of welds — Specimen dimensions and procedure for
tensile shear testing resistance spot and embossed projection welds
ISO 15614-12, Specification and qualification of welding procedures for metallic materials — Welding
procedure test — Part 12: Spot, seam and projection welding
ISO 17677-1, Resistance welding — Vocabulary — Part 1: Spot, projection and seam welding
ISO 18278-2, Resistance welding — Weldability — Part 2: Evaluation procedures for weldability in
spot welding
ISO 18594, Resistance spot-, projection- and seam-welding — Method for determining the transition
resistance on aluminium and steel material
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 669 and ISO 17677-1 apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— IEC Electropedia: available at http:// www .electropedia .org/
— ISO Online browsing platform: available at https:// www .iso .org/ obp
4 Material
4.1 Form
The material shall be according to ISO 209 and ISO 3522.
4.2 Types of aluminium alloys
A partial list of aluminium alloys is given in Annex C.
5 Surface conditions
Prior to welding, all surfaces shall be checked for their suitability for spot welding. The surfaces should
preferably be free from oil, grease, lubricant, visible oxidation, paint, dirt, or excessive scratches. If
necessary, appropriate surface treatment, e.g. chemical etching, shall be carried out. Unless specifically
developed for spot welding, mill-finish surfaces are generally not suitable for spot welding and may need
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. Aluminium manufacturers and component suppliers
can produce surface-treated material suitable for spot welding, e.g. with TiZr conversion coating.
In addition, coated material can be supplied with chromate or phosphate passivation. Phosphated
aluminium may be used in certain applications. Excessive quantities of dissolved gases in die-cast
material shall be avoided. These materials can be spot welded, although adjustment of the welding
parameters will generally be necessary as outlined in Annex B.
In all cases the surface condition and any surface treatment shall be recorded in the testing
documentation.
The stability of surface condition can be evaluated by measuring the transition resistance in accordance
with ISO 18594.
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oSIST prEN ISO 18595:2020
ISO/DIS 18595:2020(E)
6 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.
The 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 target weld diameter as defined
in 8.2. The use of edge distances smaller than the recommended values will adversely influence weld
quality. Edge distances smaller than the recommended values should be used only when expressly
specified. In this case the nominal weld diameter specified may be less than that given in 8.2, and
therefore due allowance needs to be made for a lower weld strength (see 10.4).
7 Electrodes
7.1 Materials
The electrode materials shall be copper alloy and should possess high thermal and electrical conductivity
and shall comply with, and be used in accordance with ISO 5182. If other electrode materials are used
then these shall be recorded in the testing documentation.
7.2 Dimensions
The welding electrodes shall be of sufficient cross-sectional area and strength to carry the welding
current and electrode force without overheating, excessive deformation, or excessive deflection. If
possible, from the point of accessibility, electrodes with a minimum diameter, D, of 20 mm should be
used. If other electrode diameters are used then these shall be recorded in the testing documentation.
The electrode dimensions shall, where practicable, conform to ISO 5184 for straight electrodes,
ISO 5821 for female electrode caps, or ISO 5830 for male electrode caps, as applicable. In cases where
these standards do not apply, the dimensions of the electrode shall be specified such that welds
conforming to this International Standard are produced.
It is recommended to employ either radiused electrodes or electrodes with a tip diameter greater than
the target weld diameter d.
When welding two sheets of dissimilar thickness, the electrode dimensions and the required weld
diameter should be specified with reference to the thickness of the thinner sheet. In the case of three
thicknesses, the thinner sheet of each combination should be used as the reference.
The electrode tip geometry and target weld diameter requirement shall be recorded in the testing
documentation.
During normal production, electrodes tend to wear, leading to an increase in electrode tip diameter and
damage to the tip surface geometry. The condition of at least one of the electrodes should not be allowed
to deteriorate to a level that results in a reduction in weld diameter to less than the acceptable minimum,
e.g. 4 t . When this diameter has been reached (if not earlier), the electrode shall be replaced or
restored to its initial diameter and geometry.
A common method to control process deterioration is to measure the increase in electrode tip geometry
(or contact rea on the sheet surface), where electrode tips of different diameters are in contact with the
piece to be welded, the permissible increase over the initial diameter shall apply to the smaller of the
two electrode tips.
A greater increase in the diameter of the electrode(s) is permissible only if tests prove that the strength
of the weld does not fall below the desired requirements, and only by specification.
In cases where adaptive control or automatic weld current increase (i.e. stepper controls), or other
forms of process control are used, a greater deterioration in electrode tip condition can be tolerated.
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