ISO 15609-5:2011

Overview

ISO 15609-5:2011 - Specification and qualification of welding procedures for metallic materials - Part 5: Resistance welding - defines the required content of a welding procedure specification (WPS) for resistance welding processes. It covers spot, seam (roll spot), projection, butt (flash/upset) and related resistance welding methods and identifies the variables that influence weld dimensions, weld nugget size, weld positioning, mechanical properties and joint geometry. The standard also points to the need to confirm applicability before using its principles for other resistance or related processes.

Key technical topics and requirements

ISO 15609-5:2011 specifies the minimum information a resistance welding WPS must include:

• Product and WPS identification and reference to the welding procedure qualification record (WPQR).
• Parent material details: designation, composition, coatings and thickness/dimensions.
• Welding process designation (per ISO 4063): e.g., spot, seam, projection, flash/upset.
• Machine specification: type and identification of welding equipment.
• Joint design: overlap, pitch, edge distance, pattern, sequence - sketches are recommended.
• Surface and edge preparation: degreasing, brushing, edge finishing.
• Welding technique: manual/mechanized/robotic, clamping, sequence, operator protection.
• Electrodes and auxiliaries: geometry, materials and applicable tolerances (referencing ISO 5184, ISO 5821, ISO 5827, ISO 8430).
• Machine parameters and control settings: power source type, transformer taps, welding current, squeeze/heat/hold/off times, number of impulses, electrode force, seam speed, cooling requirements and monitoring/recorder settings (Annex D gives parameter examples).
• Tolerance ranges and quality acceptance criteria (examples in Annexes A–C).

Practical applications and users

ISO 15609-5:2011 is used to:

• Prepare and document WPSs for production and qualification of resistance welds.
• Ensure repeatable, auditable welding practice across suppliers and manufacturing sites.
• Support welding engineers, quality managers, procedure writers, auditors and inspection bodies in automotive, rail, appliance, electronics, shipbuilding and heavy industry where resistance welding is common.
• Provide the basis for operator training, machine setup, maintenance schedules and troubleshooting (electrode maintenance, cooling systems, secondary cables).

Who will use it: welding engineers, QA/QC teams, production supervisors, welding procedure qualified professionals and conformity assessors.

Related standards

• ISO 15607 (general WPS rules)
• ISO 15614-12 / ISO 15614-13 (Welding procedure tests for spot/seam/projection and butt/flash)
• ISO 4063 (welding process nomenclature)
• ISO 669, ISO 17677-1, ISO 5183, ISO 5184, ISO 5821, ISO 5827, ISO 8205, ISO 8430, ISO 14327

Keywords: ISO 15609-5:2011, resistance welding WPS, welding procedure specification, spot welding, seam welding, projection welding, flash welding, welding qualification, WPQR, weld nugget, machine parameters.