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AWS C1.1M/C1.1:2019 Recommended Practices for Resistance Welding
standard by American Welding Society, 07/01/2019
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Availability date: 01/03/2022
6th Edition
Supersedes AWS C1.1M/C1.1:2012
Prepared by the American Welding Society (AWS) C1 Committee on Resistance Welding
Under the Direction of the AWS Technical Activities Committee
Approved by the AWS Board of Directors
This Recommended Practices is a collection of data and procedures that are intended to assist the user in setting up resist- ance welding equipment to produce resistance welded production parts. While the recommendations included are not expected to be final procedures for every production part or every welding machine, they serve as starting points from which a user can establish acceptable welding machine settings for specific production welding applications.
In some cases, recommended machine data is not available. In these instances, some description of the process is given to assist the reader in determining if the process might be suitable for the application.
AWS C1.1M/C1.1:2019
AWS C1.1M/C1.1:2019
ISBN Print: 978–1–64322–028–4
ISBN PDF: 978–1–64322–029–1
©2019 by American Welding Society
All rights reserved Printed in the United States of America
Photocopy Rights. No portion of this standard may be reproduced, stored in a retrieval system, or transmitted in any form, including mechanical, photocopying, recording, or otherwise, without the prior written permission of the copyright owner.
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Authorization to photocopy items for internal, personal, or educational classroom use only or the internal, personal, or educational classroom use only of specific clients is granted by the American Welding Society provided that the appropri- ate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, tel: (978) 750–8400; Internet: www.copyright.com.
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All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American Welding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of the American National Standards Institute (ANSI). When AWS American National Standards are either incorporated in, or made part of, documents that are included in federal or state laws and regulations, or the regulations of other governmen- tal bodies, their provisions carry the full legal authority of the statute. In such cases, any changes in those AWS standards must be approved by the governmental body having statutory jurisdiction before they can become a part of those laws and regulations. In all cases, these standards carry the full legal authority of the contract or other document that invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirements of an AWS stand- ard must be by agreement between the contracting parties.
AWS American National Standards are developed through a consensus standards development process that brings together volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the proc- ess and establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, or verify the accuracy of any information or the soundness of any judgments contained in its standards.
AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential, or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this standard. AWS also makes no guarantee or warranty as to the accuracy or completeness of any information pub- lished herein.
In issuing and making this standard available, AWS is neither undertaking to render professional or other services for or on behalf of any person or entity, nor is AWS undertaking to perform any duty owed by any person or entity to someone else. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the advice of a competent professional in determining the exercise of reasonable care in any given circumstances. It is assumed that the use of this standard and its provisions is entrusted to appropriately qualified and competent personnel.
This standard may be superseded by new editions. This standard may also be corrected through publication of amend- ments or errata, or supplemented by publication of addenda. Information on the latest editions of AWS standards includ- ing amendments, errata, and addenda is posted on the AWS web page (www.aws.org). Users should ensure that they have the latest edition, amendments, errata, and addenda.
Publication of this standard does not authorize infringement of any patent or trade name. Users of this standard accept any and all liabilities for infringement of any patent or trade name items. AWS disclaims liability for the infringement of any patent or product trade name resulting from the use of this standard.
AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.
Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request, in writing, to the appropriate technical committee. Such requests should be addressed to the American Welding Society, Attention: Managing Director, Standards Development, 8669 NW 36 St, # 130, Miami, FL 33166 (see Annex B). With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be rendered. These opinions are offered solely as a convenience to users of this standard, and they do not constitute professional advice. Such opinions represent only the personal opinions of the particular individuals giving them. These individuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations of AWS. In addi- tion, oral opinions are informal and should not be used as a substitute for an official interpretation.
This standard is subject to revision at any time by the AWS C1 Committee on Resistance Welding. It must be reviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations, additions, or deletions) and any pertinent data that may be of use in improving this standard are requested and should be addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS C1 Committee on Resistance Welding and the author of the comments will be informed of the Committee’s response to the comments. Guests are invited to attend all meetings of the AWS C1 Committee on Resistance Welding to express their comments verbally. Procedures for appeal of an adverse decision concerning all such comments are provided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained from the American Welding Society, 8669 NW 36 St, # 130, Miami, FL 33166.
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AWS C1 Committee on Resistance Welding
B. Kelly, Chair Kelly Welding Solutions PC
W. F. Qualls, Vice Chair Consultant
M. Diaz, Secretary American Welding Society
T. W. Alexander Centerline (Windsor) Ltd.
W. H. Brafford Consultant
R. K. Cohen Weld Computer Corporation
M. Cubert Space Exploration Technologies
R. Michelena T. J. Snow Company, Inc.
D. Wellman Obara Corporation
Advisors to the AWS C1 Committee on Resistance Welding
B. J. Bastian Benmar Associates
K. Hofman Roman Engineering Services
Kimchi Edison Welding Institute
D. F. Maatz R&E Engineering Services
S. Scotchmer Huys Industries Limited
D. C. Sorenson Entron Controls, LLC
M. Tumuluru U.S. Steel
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This foreword is not part of this standard, but is included for informational purposes only.
The data contained in these Recommended Practices have been compiled by the AWS Committee on Resistance Welding, by reviewing the data in the previous documents, by canvassing users of the resistance welding processes and correlating the data thus obtained. The resulting welding schedules shown in the tables were circulated for comments and, in addi- tion, some tests were conducted to ascertain that welds of the specified strengths could be obtained.
The present edition of Recommended Practices represents an updated combination and extension of data presented in the previous edition of AWS C1.1M/C1.1:2012, Recommended Practices for Resistance Welding. Practices for new materials have been added and practices for materials which are not currently resistance welded in commercial production have been deleted. The new materials include high-strength low-alloy steels, both coated and uncoated.
The AWS C1 Committee on Resistance Welding has prepared these Recommended Practices in the hope that they will serve as an incentive for industry to develop methods and procedures improving upon the practice presented herein; which will permit the raising of quality and performance standards. If this is achieved, the Committee will have been amply repaid for the time and effort it has devoted to this work.
A vertical line in the margin and underlined text in clauses, tables, or figures indicates an editorial or technical change from the 2012 edition.
Comments and suggestions for the improvement of this standard are welcome. They should be sent to the Secretary, AWS C1 Committee on Resistance Welding, American Welding Society, 8669 NW 36 St, Miami, FL 33166.
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Page No.
Personnel v
Foreword vii
List of Tables xi
List of Figures xiii
General Requirements 1
Scope 1
Units of Measurement 1
Safety 1
Normative References 2
Terms and Definitions 2
Resistance Spot and Seam Welding 3
Uncoated Carbon and Low-Alloy Steels 3
Coated Carbon and Low-Alloy Steels 12
Aluminum Alloys 14
Stainless Steels, Nickel, Nickel-Base, and Cobalt-Base Alloys 20
Copper and Copper Alloys 23
Titanium and Titanium Alloys 23
Welding Data Comments and Discussions Applicable to Various Metals 27
Weld Discrepancies and Causes 46
Weld Quality and Mechanical Property Tests 48
Projection Welding 70
Introduction 70
Embossed Projection Welding 72
Solid Projection Welding 78
Multiple Projection Welding 80
Weld Quality and Mechanical Property Tests 80
Flash Welding 80
Introduction 80
Equipment 81
Welding Variables 85
Welding Variable Measurements 88
Classification of Steels for Flash Welding 89
Joint Preparation and Cleaning 89
Welding Schedules 91
Weld Discrepancies and Causes 91
Weld Quality and Mechanical Property Tests 94
Upset Welding 95
Introduction 95
Equipment 95
Welding Variables 95
Joint Preparation and Cleaning 95
AWS C1.1M/C1.1:2019
Welding Parameters 95
Weld Quality and Mechanical Property Tests 95
Weld Bonding 96
Introduction 96
Aluminum Alloys 96
Other Metals 97
Weld Bonding Quality and Mechanical Property Tests 99
Equipment Monitoring and Maintenance 100
Annex A (Informative)—Informative References 111
Annex B (Informative)—Requesting an Official Interpretation on an AWS Standard 113
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List of AWS C1 Documents for Resistance Welding 115
Table Page No.
Spot-Welding Parameters for Bare, Galvanneal, and Galvanized Low-Carbon Steel
<350 MPa [72 ksi] Ultimate Tensile Strength 5
Pulsation Spot-Welding Parameters for Low-Carbon Steel 6
Seam—Welding Parameters for Bare, Galvanneal, and Galvanized Low-Carbon Steel
>300 MPa [44 ksi] Ultimate Tensile Strength 7
Spot-Welding Parameters for Bare, Galvanneal, and Galvanized Low-Carbon Steel
350~700 MPa [50–100 ksi] Ultimate Tensile Strength 8
Spot-Welding Parameters for Bare, Galvanneal, and Galvanized Low-Carbon Steel
>700 MPa [<101 ksi] Ultimate Tensile Strength 9
Spot-Welding Parameters for Low-Alloy and Medium-Carbon Steels 10
Electrode Materials for Resistance Welding 11
Basic Aluminum Alloy Groups 15
Resistance Weldability Chart for Commonly Used Combinations of Aluminum Alloys
(Based On Equal Thickness) 16
Recommended Spot-Weld Spacing, Edge Distance, Overlap, and Distance between Rows of
Welds for Aluminum and Its Alloys 19
Spot-Welding Parameters for Aluminum Alloys on Standard Single-Phase A-C Type Equipment 20
Spot-Welding Parameters for Aluminum Alloys on Single-Phase A-C Slope Control
Type Machines 21
Spot-Welding Parameters for Aluminum Alloys on Three-Phase Rectifier-Type Equipment 22
Spot-Welding Parameters for Aluminum Alloys on Three-Phase Frequency Converter-Type
Equipment (Single Impulse Welds) 24
Spot-Welding Parameters for Stainless Steels 25
Pulsation Spot-Welding Parameters for Stainless Steels 26
Seam-Welding Parameters for Stainless Steels 27
Spot-Welding Parameters for Annealed Nickel–Copper Alloy on Single-Phase Equipment 28
Spot-Welding Parameters for Annealed Nickel–Copper Alloy on Three-Phase Frequency
Converter Machines 29
Seam-Welding Parameters for Annealed Nickel–Copper Alloy on Single-Phase Equipment 30
Seam-Welding Parameters for Annealed Nickel–Copper Alloy on Three-Phase Frequency
Converter Machines 33
Spot-Welding Parameters for Annealed Nickel–Chromium Alloy 600 on Single-Phase Equipment 34
Spot-Welding Parameters for Annealed Nickel–Chromium Alloy X750 on Single-Phase
Equipment 35
Spot-Welding Parameters for Annealed Nickel–Chromium Alloy X750 on Three-Phase
Frequency Converter Machines 36
Spot-Welding Parameters for Annealed Nickel–Chromium Alloy X750 on Three-Phase
Dry Disk Rectifier Machines 37
Seam-Welding Parameters for Annealed Nickel–Chromium Alloy X750 on Single-Phase
Equipment 38
Seam-Welding Parameters for Annealed Nickel–Chromium Alloy X750 on Three-Phase
Frequency Converter Machines 39
Roll-Spot-Welding Parameters for Annealed Nickel–Chromium Alloy X750 on Three-Phase
Dry Disk Rectifier Machines 40
Spot-Welding Parameters for Annealed Nickel on Single-Phase Equipment 41
AWS C1.1M/C1.1:2019
Spot-Welding Parameters for Nickel–Iron–Chromium Alloys 42
Seam-Welding Parameters for Nickel–Iron–Chromium Alloys 42
Seam-Welding Parameters for Cobalt–Chromium–Nickel Alloys 42
Spot-Welding Parameters for Various Copper Alloys 43
Spot-Welding Parameters for Titanium Alloy 6% Al–4% V 43
Variation of Current Density and Unit Force Due to Lack of Electrode Tip Maintenance 44
Spot-Welding Parameters for Various Thickness Combinations and Arrangements of
Uncoated and Coated-Carbon and Low-Alloy Steels 45
Projection and Die Geometries for Welding a Range of Heavy-Gauge Steels 73
Process Requirements for Projection Welding a Range of Heavy-Gauge Steels 74
Punch Design Data for Low-Carbon Steel Projections 75
Die Button Design Data for Low-Carbon Steel Projections 76
Punch and Die Design Data for Forming Projections on Stainless Steel 77
Projection Welding Parameters for Low-Carbon Steel 78
Projection Welding Parameters for Galvanized Low-Carbon Steel 78
Projection Welding Parameters for Stainless Steels 79
Projection Designs and Process Requirements for Annular Projection Welding Some
Representative Light-Gauge Steels 79
Projection Welding Design Data for Stainless Steels 82
Embossed Projections for Low-Carbon Steel 83
Process Requirements for Cross-Wire Welding a Range of Thicknesses of Hot- and
Cold-Drawn Steel Wires 84
Data for Flash Welding of Tubing and Flat Sheets 92
Data for Flash Welding of Solid Round, Hex, Square, and Rectangular Bars 93
Weld-Bonding Surface Preparation for Aluminum Alloys by Low-Voltage Anodizing 97
Comparison between Resistance Spot-Welding and Weld-Bonding of Aluminum Alloys 98
Typical Spot-Welding Parameters for 1.6 mm [0.063 in] Thick 7075-T6 Aluminum Treated
with a Low-Voltage Anodizing Process 98
Commonly Used Metric Conversions Inch-Millimeter Conversion 99
Spot-Welding Parameters for Uncoated AHSS Using AC Welding Machine for IISI Group 3
And 4 Steels 109
Spot-Welding Parameters for Coated AHSS Using AC Welding Machine for IISI Group 3
And 4 Steels 109
Spot-Welding Parameters for Uncoated AHSS Using MFDC Welding Machine for IISI Group 3
And 4 Steels 110
Spot-Welding Parameters for Coated AHSS Using MFDC Welding Machine for IISI Group 3
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And 4 Steels 110
Figure Page No.
Coring in Nickel Alloy 718 (UNS N07718) Resistance Seam Weld, 200X 23
Standard RWMA Nose or Tip Geometries of Spot-Welding Electrodes 31
ISO 5821 Female Electrode Cap Designations 32
Peel Test 50
Peel Test Specimens 51
Measurement of a Weld Button Resulting from the Peel Test 52
Fracture or Pullout Modes of Weld Buttons 52
Bend Test Specimen 53
Chisel 54
Tension-Shear Test Specimen 55
Spot Welds in Sheet 56
Twisting Angle at Fracture in Tension Shear Test 56
Cross-Tension Test Specimens 58
Fixture for Cross-Tension Test (for Thicknesses up to 4.8 mm [0.19 in]) 59
Fixture for Cross-Tension Test (for Thicknesses 4.8 mm [0.19 in] and Over) 60
U-Test Specimen 61
U-Tension Test Jig 62
18a Pull Test (90-Degree Peel Test)—Single Weld 62
18b Pull Test (90-Degree Peel Test)–Dual Weld 63
Test Specimen and Typical Equipment for Torsion-Shear Test 64
Drop-Impact Test Specimen 66
Drop-Impact Test Machine 67
Test Fixture for Shear-Impact Loading Test 67
Test Fixture for Tension-Impact Loading Test 68
Fatigue Testing Machine 69
Pillow Test for Seam Welds 70
Typical Stack-up Configuration for Embossed Projection Welding of Sheet 71
Typical Configuration for Solid Projection Welding 71
Diagram Defining How Set-Down is Estimated on Cross-Wire Welds 80
Characteristics of Projection Collapse during Annular Projection Welding with Different
Base-Projection Widths 81
Chart of Flash Welding Definitions 86
Chart of Flash Welding Definitions 87
Flash Welding of Tubing and Flat Sheets 90
Flash Welding of Solid Round, Hex, Square, and Rectangular Bars 90
Comparison of Tensile-Shear Strengths of Uncured and Cured (Single Spot) Weld-Bonded
Joints of 7075-T6 Aluminum Alloy 100
Comparison of Fatigue Test Results of Weld-Bonded and Adhesive-Bonded Joints of
7075-T6 Aluminum Alloy 101
Fatigue Test Specimen of Weld-Bonded and Adhesive-Bonded Joints 102
Form for Resistance Welding Data Sheet for Spot and Projection Welding 106
Form for Resistance Welding Data Sheet for Seam Welding 107
Form for Resistance Welding Data Sheet for Flash or Upset Welding 108