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1、BRITISH STANDARD BS 2630:1982 Incorporating Amendment Nos. 1 and 2 Specification for Resistance projection welding of uncoated low carbon steel sheet and strip using embossed projections UDC 621.791.763.2:669.15-194-41 Licensed Copy: sheffieldun sheffieldun, na, Tue Nov 28 13:51:42 GMT+00:00 2006, U
2、ncontrolled Copy, (c) BSI BS 2630:1982 This British Standard, having been prepared under the direction of the Welding Standards Committee, was published under the authority of the Executive Board and comes into effect on 30 April 1982 BSI 01-2000 First published August 1955 First revision April 1982
3、 The following BSI references relate to the work on this standard: Committee reference WEE/29 Draft for comment 80/74395 DC ISBN 0 580 12719 2 Cooperating organizations The Welding Standards Committee, under whose direction this British Standard was prepared, consists of representatives from the fol
4、lowing: Aluminium Federation Associated Metal Workers Union Associated Offices Technical Committee British Compressed Gases Association British Constructional Steelwork Association British Railways Board British Shipbuilders British Steel Industry* Crown Agents for Overseas Governments and Administr
5、ations Health and Safety Executive Institution of Civil Engineers Institution of Electrical Engineers Institution of Production Engineers Institution of Structural Engineers Lloyds Register of Shipping Ministry of Defence* Process Plant Association Society of British Aerospace Companies Limited Soci
6、ety of Motor Manufacturers and Traders Limited* Water-tube Boilermakers Association Welding Institute* Welding Manufacturers Association* The organizations marked with an asterisk in the above list, together with the following, were directly represented on the Technical Committee entrusted with the
7、preparation of this British Standard: Coopted members Amendments issued since publication Amd. No.Date of issueComments 4109October 1982 7331August 1992Indicated by a sideline in the margin Licensed Copy: sheffieldun sheffieldun, na, Tue Nov 28 13:51:42 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS
8、2630:1982 BSI 01-2000i Contents Page Cooperating organizationsInside front cover Forewordii 1Scope1 2References1 3Definitions1 4Parent metal1 5Surface conditions1 6Edge conditions and form of component1 7Form of projection1 8Materials for electrode assembly1 9Design of electrode assembly1 9.1Contact
9、 face1 9.2Inserts1 9.3Cooling2 9.4Location of components2 9.5Properties2 10Weld assessment: type tests2 10.1General2 10.2Test pieces2 10.3Test methods2 10.4Number of tests2 10.5Test requirements3 10.6Acceptance requirements4 11Weld assessment: routine tests4 11.1General4 11.2Frequency of testing4 11
10、.3Test pieces and test methods5 11.4Number of tests5 11.5Test requirements5 12Routine inspection of welded components5 13Reclamation5 14Facilities for inspection5 15Testing facilities5 Appendix A Recommendations for welding equipment6 Appendix B Recommended projections to be formed in uncoated low c
11、arbon steel sheets of thickness 0.4 mm to 3.0 mm6 Appendix C Typical projection welding conditions6 Appendix D Typical information to appear on a welding procedure sheet for projection welding6 Figure 1 Shear test piece2 Figure 2 Cross tension test piece3 Figure 3 Jigging arrangement for cross tensi
12、on test piece4 Table 1 Dimensions of shear test piece3 Table 2 Dimensions of cross tension test piece3 Table 4 Typical welding conditions using type A projections6 Publications referred toInside back cover Licensed Copy: sheffieldun sheffieldun, na, Tue Nov 28 13:51:42 GMT+00:00 2006, Uncontrolled C
13、opy, (c) BSI BS 2630:1982 ii BSI 01-2000 Foreword This revision of BS 2630 has been prepared under the direction of the Welding Standards Committee. It forms one of a series of standards relating to resistance welding processes. In a standard of this type, which covers a wide range of applications,
14、it is not practicable to set out specific requirements for equipment or welding conditions to be used. However guidance on these subjects is given in appendices. It is also not possible to specify acceptance requirements. These are given in the relevant application standard to which reference should
15、 be made or, where none exists, by agreement between the contracting parties. This edition gives revised requirements for the parent metal and for test procedures and more guidance has been given with regard to machine setting. BS 2630:1955 is withdrawn. A British Standard does not purport to includ
16、e 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 cover, an inside front cover, pages i
17、 and ii, pages 1 to 6, 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 sheffieldun, na, Tue Nov 28 13:51:42 GMT+00:
18、00 2006, Uncontrolled Copy, (c) BSI BS 2630:1982 BSI 01-20001 1 Scope This British Standard specifies requirements for resistance projection welding using embossed projections in the fabrication of assemblies in uncoated low carbon steel where the single sheet thickness of the components to be welde
19、d lies within the range 0.4 mm to 3.0 mm. Appendix A gives recommendations for appropriate welding equipment. Appendix B refers to BS EN 28167. Appendix C provides guidance on welding conditions. This standard does not apply to the welding of sheets of dissimilar thickness where the thickness ratio
20、is greater than 4 to 1. 2 References The titles of the publications referred to in this standard are listed on the inside back cover. 3 Definitions For the purposes of this British Standard, the definitions given in BS 499-1 apply. 4 Parent metal Low carbon steel shall be flat rolled in coil or cut
21、length form. The thicknesses shall be from 0.4 mm to 3.0 mm. The material shall comply with the general requirements and chemical composition specified in BS 1449-1 for material grades 1, 2, 3 and 4. NOTEGrades 1 to 4 are readily weldable but in certain applications modified procedures may be necess
22、ary when welding steels at the higher compositional limits and of single sheet thicknesses less than approximately 0.6 mm. 5 Surface conditions Prior to welding, all surfaces to be projection welded shall be free from grease, scale, rust, paint, dirt or excessive pitting. NOTECertain surface treatme
23、nts such as the application of rust prevention treatment, oiling or plating may be applied before welding provided that the coating is uniform in thickness and that it has been proved that consistent welds which comply with this standard can be obtained. 6 Edge conditions and form of component The s
24、urfaces of the components shall be free from unwanted burrs or other defects which would in any way interfere with the proper collapse of the projection during welding or cause current to flow other than through the projections. The form of the components shall be such that collapse of the projectio
25、n during welding can take place without restraint from surface contacts other than at the projections. The shape of the components to be welded shall be such that, and shall be so maintained that, when correctly shaped dies, electrodes or inserts are used, the welding pressure is equally distributed
26、 over all the projections. The weld shall be made on a flat mating joint interface. The distance from the edge of this interface to the centre of the weld shall be not less than 2.25B where B is the projection diameter. The pitch of the welds, i.e. the centre to centre distance of the welds shall be
27、 not less than 4.5B, and preferably greater. 7 Form of projection A design or shape of projection shall be used which will give the results specified in clauses 9 and 10. A drawing showing these shapes shall be supplied. When a number of projections are to be welded in one operation the height of th
28、e individual projections on any of the components comprising the assembly shall not vary by more than 5 % from one another. NOTERequirements for suitable projections and tolerances are given in BS EN 28167:1992. 8 Materials for electrode assembly The electrode holder shall be of copper alloy of suff
29、icient section and strength to carry the welding current and electrode pressure without overheating or deforming. NOTEThe electrode assembly can consist of an electrode holder and electrode(s) with or without insert(s). The part in contact with the workpiece shall be either the electrode(s) or the i
30、nsert(s) as recommended in Appendix A of BS 4577:1970. 9 Design of electrode assembly 9.1 Contact face. The distance between the edge of the projection and the edge of the contact face shall be not less than 0.5B (where B is the diameter of the projection specified for the appropriate sheet thicknes
31、s) and, where possible, shall be considerably greater. The form of the electrode or insert surface shall be such that there is intimate contact with the component over the contact face to give minimum contact resistance. 9.2 Inserts. Inserts shall be inserted in such a way that there is adequate mec
32、hanical support and electrical and thermal conductivity throughout their working life. Inserts made from group A materials as specified in BS 4577 shall not be brazed. NOTEInserts of more than 16 mm thickness will adversely affect the electrical and thermal characteristics of the electrode assembly.
33、 Licensed Copy: sheffieldun sheffieldun, na, Tue Nov 28 13:51:42 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 2630:1982 2 BSI 01-2000 9.3 Cooling. Because cooling is important to maintain electrode life, cooling channels shall be as close as possible to the welding interface. 9.4 Location of compon
34、ents. When using devices for locating the components, precautions shall be taken to avoid the formation of alternative paths for the current. Such devices shall not impede the free collapse of the projections during welding. 9.5 Properties. The electrode assembly shall be so designed and located in
35、the welding machine as to ensure that the pressure and current are uniformly distributed between the projections. NOTEIn general, magnetic materials should not be used in association with the electrode assembly. 10 Weld assessment: type tests 10.1 General. A procedure shall be established for each m
36、achine, for each size of component and for each material or combination of materials to be used. The record of the procedure shall be based on the appropriate items from the list given in Appendix D. The following type tests shall be carried out: a) shear test (sometimes called tensile shear); b) cr
37、oss tension test; c) torsion test (optional see 10.5.5); d) visual and metallurgical examination. 10.2 Test pieces 10.2.1 General. When practicable, actual components shall be used for testing. When it is not practicable to use actual components, test pieces from the same material shall be used and
38、sufficient material associated with the test piece shall be in the throat of the machine to approximate to the magnetic effect of the work piece under production conditions. 10.2.2 Shear test. The dimensions of shear test pieces shall be as given in Figure 1 and Table 1. 10.2.3 Cross tension test. T
39、he dimensions of cross tension test pieces shall be as given in Figure 2 and Table 2. NOTEFigure 3 shows a jigging arrangement for the cross tension test piece. 10.2.4 Torsion test. The dimensions of torsion test pieces shall be the subject of agreement between the manufacturer and the purchaser and
40、 shall be such as to provide a representative test in torsion of a weld produced in accordance with this standard. 10.2.5 Metallurgical examination. A metallographic section shall be prepared. NOTEFor this purpose, the method given in Appendix A of BS 709:1971 is recommended. 10.3 Test methods 10.3.
41、1 Shear test, cross tension test and torsion test. Tests shall be carried out in shear, cross tension and, where relevant, in torsion, to enable these characteristics to be assessed in accordance with the requirements of 10.5.3, 10.5.4 and 10.5.5. 10.3.2 Metallurgical examination. The examination of
42、 the metallographic section shall be carried out under a microscope having a magnification of not less than 10. 10.4 Number of tests. The number of type tests shall be sufficient to establish quantitative data in each case. Figure 1 Shear test piece Licensed Copy: sheffieldun sheffieldun, na, Tue No
43、v 28 13:51:42 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 2630:1982 BSI 01-20003 Table 1 Dimensions of shear test piece Table 2 Dimensions of cross tension test piece 10.5 Test requirements 10.5.1 Weld diameter. The mean weld diameter shall be measured from the shear test, the cross tension test a
44、nd, where relevant, the torsion test. It shall not fall below 1.5 the projection diameter B unless the requirements of the appropriate application standard permit this (see 10.6). NOTEThe mean weld diameter is taken to be the average of two diameters measured at right angles, one of which is the app
45、arent minimum diameter. 10.5.2 Weld fracture mode. All welds made on test pieces having a single sheet thickness of up to 2 mm shall pull a slug in the shear and cross tension tests. NOTEAbove this thickness, face fractures may be accepted by agreement between the manufacturer and the purchaser. 10.
46、5.3 Shear test. The weld shall be assessed by the force to fracture and by the weld fracture mode (see 10.5.2). 10.5.4 Cross tension test. The weld shall be assessed by the force to fracture and by the weld fracture mode (see 10.5.2). 10.5.5 Torsion test (optional). By agreement between the manufact
47、urer and the purchaser, a torsion test may be carried out. In this case the weld shall be assessed by the maximum torque or angle to failure. 10.5.6 Visual and metallurgical examination. A description of the visual appearance of the test area before metallurgical examination, particularly any weld d
48、efects present, shall be reported. In the metallurgical examination the type and location of any weld defects shall be reported. NOTEThe standard of defects permissible, revealed as a result of visual and metallurgical examination, should be as specified (see 10.6) in the appropriate application sta
49、ndard or, where none exists, by agreement between the manufacturer and the purchaser. Sheet thickness Overlap, (a)Width, (b)Overall length, (c)Unclamped length, (d) Over Up to and including mmmmmmmmmmmm 0.4a1.53545 (30) 17595 1.53.04560 (30) 230105 NOTEFigures for widths in parentheses will give approximately 10 % reduction in strength and these widths may only be used by agreement between the manufacturer and the purchaser. a This range includes the thickness 0.4 mm as the lower limit. Figure 2 Cross tension test piece Sheet thickness Width, (b) Overal
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