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1、BRITISH STANDARD BS 1140:1993 Specification for Resistance spot welding of uncoated and coated low carbon steel UDC 669.141.24:621.791.763.1 Licensed Copy: sheffieldun sheffieldun, na, Fri Nov 24 06:19:50 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 1140:1993 This British Standard, having been prep
2、ared under the direction of the Welding Standards Policy Committee, was published under the authority of the Standards Board and comes into effect on 15 May 1993 BSI 12-1998 First published October 1943 Second edition October 1946 Third edition November 1957 Fourth edition June 1980 Fifth edition Ma
3、y 1993 The following BSI references relate to the work on this standard: Committee reference WEE/29 Draft for comment 90/71477 DC ISBN 0 580 21944 5 Committees responsible for this British Standard The preparation of this British Standard was entrusted by the Welding Standards Policy Committee (WEE/
4、-) to Technical Committee WEE/29, upon which the following bodies were represented: British Steel Industry Railway Industry Association of Great Britain Society of Motor Manufacturers and Traders Ltd. Welding Institute Welding Manufacturers Association (BEAMA Ltd.) Coopted members Amendments issued
5、since publication Amd. No.DateComments Licensed Copy: sheffieldun sheffieldun, na, Fri Nov 24 06:19:50 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 1140:1993 BSI 12-1998i Contents Page Committees responsibleInside front cover Forewordiii 1Scope1 2References1 3Definitions1 4Items to be agreed betwee
6、n the contracting parties3 5Parent metal3 5.1Uncoated steel3 5.2Hot-dip zinc and iron-zinc coated steel3 5.3Electrolytic zinc coated steel3 5.4Electrolytic zinc-nickel coated3 5.5Terne coated steel (nominal Pb/10 % Sn coating)3 5.6Aluminium coated steel3 5.7Zinc-55 % aluminium coated steel3 5.8Zinc-
7、5 % aluminium coated steel3 6Surface conditions4 7Edge conditions, form of component and weld pitch4 8Electrodes5 8.1Materials5 8.2Dimensions5 8.3Cooling5 9Weld assessment General5 9.1Procedure5 9.2Type tests6 9.3Routine tests7 10Weld assessment Tests7 10.1General7 10.2Shear test7 10.3Cross-tension
8、test (optional)7 10.4Peel test or chisel test9 10.5Visual examination9 10.6Metallurgical examination10 10.7Hardness test (optional)10 11Weld assessment Acceptance criteria10 11.1General10 11.2Weld dimensions10 11.3Weld appearance10 11.4Weld diameter10 11.5Weld fracture mode10 11.6Distortion10 12Rout
9、ine inspection of welded components10 13Facilities for inspection11 14Testing facilities11 Annex A (informative) Recommendations for spot welding equipment12 Annex B (informative) Typical spot welding conditions12 Annex C (normative) Typical information to appear on a welding procedure sheet for spo
10、t welding15 Annex D (informative) Calculation of weld strength16 Licensed Copy: sheffieldun sheffieldun, na, Fri Nov 24 06:19:50 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 1140:1993 ii BSI 12-1998 Page Figure 1 Measurement of weld size2 Figure 2 Minimum pitch for welds in uncoated low carbon stee
11、l sheet thickness 0.4 mm to 12 mm4 Figure 3 Schematic weldability lobe6 Figure 4 Shear test piece8 Figure 5 Cross-tension test piece8 Figure 6 Jigging arrangement for cross-tension test piece9 Table 1 Dimensions of shear test piece7 Table 2 Dimensions of cross-tension test piece7 Table B.1 Typical s
12、pot welding conditions for uncoated low carbon steel sheet of thickness 0.4 mm to 3.0 mm13 Table B.2 Typical spot welding conditions for uncoated low carbon steel plate of thickness 3.0 mm to 12.0 mm using a single-phase a.c. machine13 Table B.3 Typical spot welding conditions for uncoated low carbo
13、n steel strips or plates of thickness 3.0 mm to 12.0 mm using a three-phase a.c. machine13 Table B.4 Typical spot welding conditions for hot-dip zinc, zinc-5 % aluminium, zinc-55 % aluminium and electrolytically deposited zinc coated steel sheets of combined thickness 0.4 mm to 3.0 mm14 Table B.5 Ty
14、pical spot welding of double sided iron-zinc alloy and zinc-nickel alloy coated steels of sheet thickness 0.4 mm to 3.0 mm14 Table B.6 Typical spot welding conditions for two terne coated steel sheets of thickness 0.4 mm to 1.6 mm15 Table B.7 Typical spot welding conditions for aluminium coated stee
15、l sheet of thickness 0.4 mm to 2.0 mm15 Table D.1 Typical minimum weld strength values (shear to failure) for low carbon steel of 280 N/mm2 minimum tensile strength16 List of referencesInside back cover Licensed Copy: sheffieldun sheffieldun, na, Fri Nov 24 06:19:50 GMT+00:00 2006, Uncontrolled Copy
16、, (c) BSI BS 1140:1993 BSI 12-1998iii Foreword This revision of BS 1140 has been prepared under the direction of the Welding Standards Policy Committee. BS 1140 was first published in 1943, being subsequently revised in 1946, 1957 and 1980. It forms one of a series of standards on resistance process
17、es. The applications of the spot welding process are so wide that it is not practicable to give specific welding conditions. However, a series of annexes gives information designed to assist the choice of welding conditions where these are not specified in a relevant application standard. A British
18、Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for their correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. Summary of pages This document comprises a front co
19、ver, an inside front cover, pages i to iv, pages 1 to 16, an inside back cover and a back cover. This standard has been updated (see copyright date) and may have had amendments incorporated. This will be indicated in the amendment table on the inside front cover. Licensed Copy: sheffieldun sheffield
20、un, na, Fri Nov 24 06:19:50 GMT+00:00 2006, Uncontrolled Copy, (c) BSI iv blank Licensed Copy: sheffieldun sheffieldun, na, Fri Nov 24 06:19:50 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 1140:1993 BSI 12-19981 1 Scope This British Standard specifies procedures for resistance spot welding in the f
21、abrication of assemblies of uncoated and coated low carbon steel comprising two or three thicknesses of metal, where the single sheet thickness of the components to be welded is within the following ranges: a) uncoated sheets: 0.4 mm to 3.0 mm (see 5.1); b) uncoated plates: 3.0 mm to 12.0 mm (see 5.
22、1); c) hot-dip zinc coated sheets: 0.4 mm to 3.0 mm (see 5.2); d) hot-dip iron-zinc alloy coated sheets (galvaneal): 0.4 mm to 3.0 mm (see 5.2); e) electrolytic zinc coated sheets: 0.4 mm to 3.0 mm (see 5.3); f) electrolytic zinc-nickel coated sheets: 0.4 mm to 3.0 mm (see 5.4); g) terne coated shee
23、ts: 0.4 mm to 3.0 mm (see 5.5); h) aluminium coated sheets: 0.4 mm to 3.0 mm (see 5.6); i) hot-dip zinc-55 % aluminium coated sheets 0.4 mm to 3.0 mm (see 5.7); j) hot-dip zinc-5 % aluminium coated sheets 0.4 mm to 3.0 mm (see 5.8). Guidance on the choice of appropriate welding equipment and approxi
24、mate spot welding conditions is given in annexes A and B respectively. This procedure does not apply to the welding of sheets or plates of dissimilar thickness where the thickness ratio is greater than 3 to 1. In addition to the definitive requirements, this standard also requires the items detailed
25、 in clause 4 to be documented. For compliance with this standard, both the definitive requirements and the documented items have to be satisfied. 2 References 2.1 Normative references This British Standard incorporates, by reference, provisions from specific editions of other publications. These nor
26、mative references are cited at the appropriate points in the text and the publications are listed on the inside back cover. Subsequent amendments to, or revisions of, any of these publications apply to this British Standard only when incorporated in it by updating or revision. 2.2 Informative refere
27、nces This British Standard refers to other publications that provide information or guidance. Editions of these publications current at the time of issue of this standard are listed on the inside back cover, but reference should be made to the latest editions. 3 Definitions For the purposes of this
28、British Standard, the following definitions apply. For other technical terms applicable to this British Standard, the definitions given in BS 499-1:1991 apply. 3.1 weld size the average weld diameter 3.2 weld nugget a zone in a resistance weld where the metal has been melted 3.3 nominal weld diamete
29、r the diameter of the plug (slug) measured at the base of the nugget (see Figure 1) 3.4 cross-tension test a test to determine the tensile force that the weld can sustain 3.5 shear test a test to determine the shear force that the weld can sustain 3.6 corona bond the area of the weld at the faying s
30、urfaces, in which solid phase bonding has occurred see Figure 1b) 3.7 interface failure the fracture through the weld between the sheets at the plane of the interface 3.8 plug (slug) failure the fracture of a weld through the sheet thickness at the edge of the weld see Figure 1a) Licensed Copy: shef
31、fieldun sheffieldun, na, Fri Nov 24 06:19:50 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 1140:1993 2 BSI 12-1998 Figure 1 Measurement of weld size Licensed Copy: sheffieldun sheffieldun, na, Fri Nov 24 06:19:50 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 1140:1993 BSI 12-19983 4 Items to be agre
32、ed between the contracting parties The following items to be agreed between the contracting parties, which are specified in the clauses referred to, shall be fully documented. Both the definitive requirements specified throughout the standard and the following documented items shall be satisfied bef
33、ore a claim of compliance with this standard can be made and verified: a) whether weld quality requirements are to be based on the application standard or annex B or are to be the subject of discussion and agreement (see clause 11); b) whether edge distances less than the specified values are to be
34、agreed (see note 2 to clause 7); c) electrode dimensions where BS 4215-2:1987 or BS EN 21089:1992 do not apply or where the single material thickness is greater than 3 mm (see 8.2.2); d) application of larger or smaller electrode tip diameters (see notes 2, 3 and 4 to 8.2.3); e) whether cross-tensio
35、n and/or hardness tests are to be carried out, and whether dynamic tests are to be carried out (see 9.2.2); f) type tests: dimensions of shear and cross-tension test pieces of a thickness other than that given in Table 1 and Table 2 respectively (see 10.2.1.2 and 10.3.1.2 respectively); g) type test
36、s and routine tests: method for hardness testing and hardness acceptance criteria (see 10.7); h) type tests: whether interface failures are acceptable (see 11.5). i) type tests: weld acceptance criteria where no appropriate application standard exists (see clause 11); j) whether it is the intention
37、of the purchaser to inspect production and testing (see clause 13). 5 Parent metal 5.1 Uncoated steel Low carbon steel shall be flat rolled in coil or cut length form and shall be free from harmful imperfections. Sheet and strip material shall conform to the general requirements and chemical composi
38、tion specified in BS 1449-1:1991. Plate material shall conform to BS 1449-1:1991 or BS 4360:1990, as relevant. NOTEGrades 1 to 4 are readily weldable, but in certain applications modified procedures may be necessary, e.g. when welding steels at the higher compositional limits. 5.2 Hot-dip zinc and i
39、ron-zinc coated steel Zinc coated steel, which is available in various base steel compositions, coating types and surface treatments, shall conform to the requirements for hot-dip zinc coated and iron-zinc coated steel coil and cut lengths, in forming and structural grades, coated by a continuous pr
40、ocess, specified in BS 2989:1992. Coating types and coating mass shall conform to BS 2989:1992, the zinc alloy coatings (also known as galvaneal) and the lower mass zinc coatings being the most readily weldable. 5.3 Electrolytic zinc coated steel Electrolytic zinc coated steel shall be produced by e
41、lectrolytic deposition of pure zinc on low carbon steel sheet and shall conform to BS 6687:1986. The maximum coating thickness per side shall be 10 m (equal to a coating mass of 71 g/m2 for each surface). 5.4 Electrolytic zinc-nickel coated steel Such coatings deposited electrolytically shall be lim
42、ited to a maximum coating thickness per side of 7 m (equal to a coating mass of 50 g/m2 for each surface). 5.5 Terne coated steel (nominally Pb/10 % Sn coating) Terne coated steel shall conform to BS 6582:1985. The maximum coating mass shall have a nominal value of 150 g/m2, including both surfaces.
43、 5.6 Aluminium coated steel Aluminium coated steel shall be produced by the hot-dip process, the coating containing 5 % to 11 % silicon, and shall conform to the relevant requirements of BS 6536:1985. NOTEA coating mass up to a nominal value of 150 g/m2, including both surfaces is considered to be t
44、he most readily weldable. 5.7 Zinc-55 % aluminium coated steel Zinc-55 % aluminium coated steel produced by the hot-dip process shall conform to BS 6830:1987. The maximum coating mass shall be 185 g/m2, including both surfaces, for the more readily weldable grades. 5.8 Zinc-5 % aluminium coated stee
45、l Zinc-5 % aluminium coated steel shall be produced by the hot-dip process. The maximum coating mass shall be 180 g/m2, including both surfaces, for the more readily weldable grades. Licensed Copy: sheffieldun sheffieldun, na, Fri Nov 24 06:19:50 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 1140:19
46、93 4 BSI 12-1998 6 Surface conditions Prior to welding, all surfaces to be spot welded shall be free from paint, grease, scale, rust, print, dirt or excessive pitting. NOTECertain surface treatments such as the application of paint primers, rust prevention treatment, oils, lubricants or plating may
47、be applied before welding, provided that the coating is uniform in thickness and that it has been proved that consistent welds that conform to this standard can be obtained. In the case of paint primers etc., reference should be made to BS 4129. Excessive use of surface pretreatment should be avoide
48、d if maximum electrode life is to be achieved. Generally, heavy phosphate pretreatments of steel are not recommended prior to spot welding. 7 Edge conditions, form of component and weld pitch The components to be welded shall be free from burrs or other imperfections which would in any way interfere
49、 with interface contact or require excessive force to fit the parts together. The shape of the component shall be such that there is proper interface contact at the areas where the welds are to be made. NOTEThe recommended distance from the edge of the component to the centre of the weld should be not less than 1.25d, where d is the recommended weld diameter as defined by: d = 5 t where t is the sheet thickness (in mm). NOTE 2Where edge distances less than the recommended values are used, these should only be by agreement between