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.
