SIST EN ISO 8166:2003

SLOVENSKI STANDARD
SIST EN ISO 8166:2003
01-december-2003
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Resistance welding - Procedure for the evaluation of the life of spot welding electrodes
using constant machine settings (ISO 8166:2003)
Widerstandsschweißen - Verfahren für das Bewerten der Standmenge von
Punktschweißelektroden bei konstanter Maschinen-Einstellung (ISO 8166:2003)
Soudage par résistance - Mode opératoire pour l'évaluation de la durée de vie des
électrodes utilisées en soudage par points avec des réglages de machines constants
(ISO 8166:2003)
Ta slovenski standard je istoveten z: EN ISO 8166:2003
ICS:
25.160.20 Potrošni material pri varjenju Welding consumables
SIST EN ISO 8166:2003 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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SIST EN ISO 8166:2003

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SIST EN ISO 8166:2003
EUROPEAN STANDARD
EN ISO 8166
NORME EUROPÉENNE
EUROPÄISCHE NORM
June 2003
ICS 25.160.20
English version
Resistance welding - Procedure for the evaluation of the life of
spot welding electrodes using constant machine settings (ISO
8166:2003)
Soudage par résistance - Mode opératoire pour l'évaluation Widerstandsschweißen - Verfahren für das Bewerten der
de la durée de vie des électrodes utilisées en soudage par Standmenge von Punktschweißelektroden bei konstanter
points avec des réglages de machines constants (ISO Maschinen-Einstellung (ISO 8166:2003)
8166:2003)
This European Standard was approved by CEN on 9 September 2002.
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 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 Management Centre has the same status as the official
versions.
CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,
Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Slovakia, Spain, Sweden, Switzerland and United
Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: rue de Stassart, 36  B-1050 Brussels
© 2003 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN ISO 8166:2003 E
worldwide for CEN national Members.

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SIST EN ISO 8166:2003
EN ISO 8166:2003 (E)
Contents
page
Foreword.3
Introduction .4
1 Scope .5
2 Normative references .5
3 Terms and definitions.5
4 Criteria for the end point of the electrode life test .6
5 Machine details .6
5.1 General.6
5.2 Machine type.7
5.3 Mechanical characteristics .7
5.4 Electrical characteristics.10
5.5 Water cooling of electrodes.10
6 Electrode details.10
7 Test procedure.11
7.1 General.11
7.2 Dimensions .11
7.3 Selection of welding conditions .12
8 Report of test results.13
Bibliography .16
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SIST EN ISO 8166:2003
EN ISO 8166:2003 (E)
Foreword
This document (EN ISO 8166:2003) has been prepared by Technical Committee CEN/TC 121 "Welding", the
secretariat of which is held by DS, 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 December 2003, and conflicting national standards shall be withdrawn at the latest
by December 2003.
According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Czech Republic, Denmark, Finland,
France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal,
Slovakia, Spain, Sweden, Switzerland and the United Kingdom.
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SIST EN ISO 8166:2003
EN ISO 8166:2003 (E)
Introduction
This European Standard enables the electrode life of spot welding electrodes to be determined. This standard does
not invalidate procedures for electrode life testing or their qualification documents in current use which complied with
the national or international standards or regulations existing at that time, provided the intent of the technical
requirement is satisfied and the specified application, its performance and equipment with which it is performed
remain unchanged.
When this standard is referenced for contractual purposes, all questions relating to the specification and
implementation of welding procedures shall be defined in the design specification at the time of enquiry or at the
contract stage.
It has been assumed in this standard that the execution of its provisions is entrusted to appropriately trained, skilled
and experienced personnel.
For the quality of welded structures the relevant part of standard EN ISO 14554 should be applicable. The
specification of procedures should follow guidelines as in standard prEN ISO 15609-5.
The specified procedure allows the determination of the life of spot welding electrodes i.e. the number of acceptable
spot welds which can be made between the need for re-dressing of the electrodes. The test procedure can be used to
evaluate the following:
a) the influence of electrode material or electrode shape and dimensions on the electrode life when welding a
particular material;
b) the affect of material being welded on the electrode life obtained using a fixed electrode shape and
dimensions;
c) the influence of welding conditions on electrode life when using a particular combination of electrode material
and shape for the welding of any material type;
d) the influence of welding machine type, electrode cooling on electrode life.
Precise details of the test procedure to be used will depend on which aspect of items a) to d) is to be evaluated
relative to the electrode life obtained.
For convenience, a generic test procedure is described in this document which allows assessment of the effect of the
material being welded on the electrode life obtained when using precisely defined welding conditions/electrode
configurations. These can be modified depending on the particular parameters being investigated.
Recommendations are also given concerning the important parameters which need to be kept constant so as to allow
the appropriate comparisons to be made as indicated in a), c) and d) above.
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SIST EN ISO 8166:2003
EN ISO 8166:2003 (E)
1 Scope
This European Standard specifies a procedure to be used for the evaluation of the life of spot welding electrodes
when welding uncoated and coated steels, stainless steels, aluminium and aluminium alloys using constant machine
settings which are not changed during the test. The procedure can also be used to establish the electrode life when
spot welding other metallic materials.
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 ISO 14273, Specimen dimensions and procedure for shear testing resistance spot, seam and embossed
projection welds (ISO 14273:2000).
prEN ISO 14329:1999, Welding — Destructive testing of welds — Failure types and geometric measurements for
resistance spot, seam and projection welds (ISO/DIS 14329:1999).
prEN ISO 15609-5, Specification and approval of welding procedures for metallic materials — Welding procedure
specification — Part 5: Resistance welding (ISO/DIS 15609-5:2000).
EN ISO 17653, Destructive tests on welds in metallic materials — Torsion of resistance spot welds (ISO 17653:2003).
ISO 669:2000, Resistance welding — Resistance welding equipment — Mechanical and electrical requirements.
ISO 5182:1991, Welding — Materials for resistance welding electrodes and ancillary equipment.
ISO 5184, Straight resistance spot welding electrodes.
ISO 5821, Resistance spot welding electrode caps.
ISO 5830, Resistance spot welding — Male electrode caps.
ISO 10447, Welding — Peel and chisel testing of resistance spot, projection and seam welds.
ISO/DIS 14373, Welding — Resistance spot welds — Procedure for spot welding of uncoated and coated low carbon
and high strength steels.
3 Terms and definitions
For the purposes of this European Standard, the terms and definitions given in ISO 669:2000 and
prEN ISO 14329:1999 apply.
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SIST EN ISO 8166:2003
EN ISO 8166:2003 (E)
4 Criteria for the end point of the electrode life test
For the purpose of this procedure for all materials, the electrode life is the number of welds which can be made giving
the required weld quality before re-machining of the electrode face is necessary.
The electrode shall be considered to have reached its life when the welds being produced have a weld diameter, as
indicated in a peel test, of less than 3,5 √t (where t is the sheet thickness in mm) for three welds in a test sample of
five consecutive welds. Peel testing shall be carried out according to ISO 10447. All electrode life tests will be
repeated three times to give an indication of the amount of scatter. Both the average value and the range of electrode
life shall be quoted. Ring or stuck welds are not acceptable. It should be noted that ring welds occur sooner when
welding coated steels.
Alternative criteria for determining the end of electrode life shall be used as defined in the design specification. These
depend on the requirements of the product. Typical examples which can be used when testing uncoated or coated
steels include:
a) agreed reduction in tensile shear force of the weld e.g., 30 %. (Shear Testing will be carried out in accordance
with EN ISO 14273);
b) agreed criteria using a torsion testing procedure according to EN ISO 17653;
c) agreed criteria based on micro-sections;
d) limits based on aesthetic requirements, e.g. surface indentation or surface marking;
e) agreed criteria based on electrode sticking.
When testing aluminium or aluminium alloys, the following criteria for the end of the electrode life can be used as
defined in the design specification. These depend on the requirements of the end product and include:
f) an agreed 30 % reduction in tensile shear force of the weld;
g) agreed criteria using a torsion testing procedure;
h) agreed criteria based on weld nugget porosity or cracking;
i) criteria based on surface cracking;
j) limits based on aesthetic requirements, e.g. surface indentation or surface marking;
k) agreed criteria based on electrode sticking.
5 Machine details
5.1 General
The electrode life is very dependent on the type of spot welding machine or gun used. It is necessary therefore to
specify various aspects of machine or gun design. Both electrical and mechanical characteristics of the welding
machine and gun shall be specified according to ISO 669.
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SIST EN ISO 8166:2003
EN ISO 8166:2003 (E)
5.2 Machine type
The spot welding machines or guns shall be a conventional 50 Hz or 60 Hz AC type with electrical and mechanical
properties specified in ISO 669. If phase shift control is used for the adjustment of the welding current, then the
required welding current shall be attained with a phase setting giving not less than 70 % of the full sinusoidal
waveform. The phase angle should be
...