EN ISO 16432:2007 PDF

Overview

EN ISO 16432:2007 (ISO 16432:2006) is a European adoption of an international standard that defines requirements and procedures for embossed resistance projection welding of uncoated and metallic-coated low carbon steels. It applies to assemblies comprising two sheet thicknesses where the maximum single sheet thickness is 0.4 mm to 3 mm. Coatings covered include hot‑dip zinc/galvannealed, electrolytic zinc (and zinc‑iron, zinc‑nickel), aluminium‑coated and zinc‑aluminium steels. Organic‑coated or primer‑coated steels are excluded.

Key topics and technical requirements

• Scope and materials: Acceptable steel forms, surface condition requirements (surfaces must be free of grease, scale, paint and contaminants) and a partial list of applicable steel grades (Annex D).
• Component and projection design: Placement of embossed projections, projection base diameter and relationships to sheet thickness (see Annex B and ISO 8167).
• Welding equipment and tooling: Requirements for welding machines, electrode assembly design (contact face, inserts, cooling), component location and tooling considerations (Annex A gives recommendations).
• Welding procedure specification: Guidance on selecting welding parameters for coated and uncoated steels; Annex C includes typical projection welding conditions (guidance only - adapt to equipment and service conditions).
• Weld assessment and testing: Type tests and routine tests covering weld diameter, fracture mode, weld strength and visual/metallographic examination. Destructive test methods and specimen dimensions reference ISO 10447, ISO 14270, ISO 14272, ISO 14273 and ISO 14329.
• Quality and repair: Frequency of routine testing, acceptance criteria and recommendations for repair of non‑conforming assemblies.
• Informative annexes: Practical guidance on equipment, projection dimensions and example welding parameters.

Applications

EN ISO 16432:2007 is intended for industries and processes where reliable projection welding of thin low carbon steel parts is required:

• Automotive body and sub‑assembly manufacturing (spot/projection welds on coated body panels)
• White goods and appliance assembly
• HVAC and ductwork fabrication
• Metal furniture, brackets and lightweight structural components
• High‑volume fabrication lines requiring standardized welding procedures and quality control

Who should use this standard

• Welding engineers and process engineers developing projection welding procedures
• Quality assurance and inspection teams verifying weld acceptance
• Tooling designers and production engineers specifying electrode design and fixture layout
• Standards bodies and procurement teams referencing welding requirements

Related standards

Normative references include: ISO 669, ISO 8167, ISO 10447, ISO 14270, ISO 14272, ISO 14273, ISO 14329, ISO 15609‑5, ISO 15614‑12 - all relevant for resistance welding equipment, projections, test methods and welding procedure qualification.

Keywords: EN ISO 16432:2007, projection welding, resistance welding, embossed projection, low carbon steel, galvannealed, welding procedure specification, projection weld testing.