WORLDWIDE

ENGINEERING
STANDARDS

Material Specification
Metals

GMW16215

Welding Acceptance Criteria and Repair Procedures: Resistance

Projection Welded Steel Nuts, Studs, Cages and Other Parts with
Solid Coined Projections

1 Scope
This specification applies to resistance projection welded steel nuts, studs, cages, and other parts with solid
coined projections.
Note: Nothing in this standard supercedes applicable laws and regulations.
Note: In the event of conflict between the English and domestic language, the English language shall take
precedence.
1.1 Purpose. This specification provides acceptance criteria for steel nuts, studs, cages and other parts with
solid projections that are resistance projection welded in automotive products that GM is responsible for
establishing or approving the product design. This specification does not cover the welding of projections that
are embossed into sheet metal.
1.2 Applicability. The criteria established in this specification become mandatory when referenced on a weld
drawing. Deviation from any weld criteria provided in this specification must be identified on a weld drawing or
other product engineering design document.
1.3 Usage. Welded fasteners are considered satisfactory when they meet the expected design service loads
and satisfy functional performance requirements. The evaluation criteria contained in this document has been
established as a basis for the manufacturing acceptance of welded products and are the same for all welds
regardless of service load. Furthermore, welds identified as discrepant often retain a percentage of their
mechanical properties and may contribute to the integrity of the welded product. Application of this
specification for other uses, such as post-crash weld quality assessment, may lead to erroneous results or
conclusions.
1.4 Clarification. For clarification of this specification or editorial comments, email the GM Weld Council at
weld.council@gm.com.

2 References
Note: Only the latest approved standards are applicable unless otherwise specified.
2.1 External Standards/Specifications.
None
2.2 GM Standards/Specifications.
GMW14058

GMW15563

3 Requirements
3.1 General Acceptance Criteria.
3.1.1 Presence and Location. A projection welded fastener that is missing or located outside the position
tolerance indicated on the assembly documentation is discrepant.
3.1.2 Set-down. Weld fasteners and cages (except fasters with ring projections) shall be set down so that the
gap between the base of the fastener and the mating part is no more than 0.3 mm or 30% of the pre-weld
projection height whichever is lesser. The welding process shall be adjusted whenever a gap is detected that
exceeds this value. Set-down is not a criterion for welds to be discrepant.

Copyright 2010 General Motors Company All Rights Reserved

September 2010

Originating Department: North American Engineering Standards

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GMW16215

3.1.3 Parallelism. The post-weld side-to-side gap between the head of a welded fastener and the mating part
shall not differ by more than 0.2 mm. The welding process shall be adjusted whenever this gap difference is
exceeded. Parallelism is not a criterion for welds to be discrepant.
3.1.4 Surface Eruptions. Welding shall not leave eruptions that are more than 0.2 mm high to the back side of
the sheet being welded. The welding process shall be adjusted (e.g., replace electrodes) whenever eruption is
detected that exceeds this value. Flatness is not a criterion for welds to be discrepant.
3.2 Visual Acceptance Criteria.
3.2.1 Cracks. A welded assembly that has a crack that is visible without magnification and located in or around
the welds is discrepant.
3.2.2 Holes. A welded assembly that has a hole that extends through any of the welds or sheets is discrepant.
3.2.3 Spatter. A welded fastener shall not have spatter on its threaded section. A fastener that has spatter on
its threaded section shall have its process adjusted to eliminate the condition. When spatter impedes
subsequent assembly, threads with spatter should be repaired.
3.3 Measurable Acceptance Criteria.
3.3.1 Nuts and Studs with Multiple Projections. The quality of a projection welded nut or stud with multiple
projections is acceptable when either the quantity of projections welded or push-out strength criteria are met. A
projection welded nut or stud having multiple projections that does not meet either of these criteria is
discrepant.
3.3.1.1 Quantity of Projections Welded. The quality of a projection welded nut or stud with multiple
projections is acceptable when the quantity of projections that show evidence of welding is equal to or greater
than the number specified in Table 1. (Push-out Load Strength is an alternative criterion.)

Number of
Projections on the Part

Number of Projections
with Evidence of Welding

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Table 1: Acceptable Quality Based on Projections with Evidence of Welding

3.3.1.2 Push-out Load Strength Criteria. The quality of a projection welded nut or stud with multiple
projections is acceptable when the tested part exceeds the push-out loads contained in Table 2. (Quantity of
projections welded is an alternative criterion.)
Table 2: Acceptable Quality Based on Push-Off Force
Weld Fastener Size

Minimum Push-Out Load (kN)

4 mm

4.0

5 mm

4.5

6 mm

5.0

8 mm

5.5

10 mm

7.0

3/8 in

7.0

7/16 in

7.8

12 mm

9.0

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3.3.2 Projection Welded Fastener with Single Ring Projection. The quality of a projection welded fastener
with a single ring projection is acceptable when Evidence of Welding exists over at least 80% of the weldable
length (projection circumference).
3.3.3 Parts with Long Projections. The quality of a projection welded part with one or two (non-ring)
projections - each of which is longer than 10 mm is acceptable when evidence of welding exists over or at least
80% of the weldable length of each projection.
3.3.4 Welded Cages. The quality of a projection welded cage is acceptable when either all projections show
evidence of welding or the cage withstands the torque shown in Table 3.
Table 3: Torque for Testing Welded Cages
Weld Fastener Size

Minimum Torque
(Nm)

8 mm

40

10 mm

60

7/16 in

85

12 mm

100

14 mm

100

Welded Cage
Caged Nut
Shoulder Bolt
Sheet Metal Part

Note: Shoulder Bolt is bottomed against Nut; Torque is applied in Tightening Direction. (Torque is not applied to outside walls of the cage.)

3.4 Disposition/Repair Procedure.

3.4.1. Disposition. Products supplied to the requirements of this standard are conforming provided the parts
as welded meet the General, Visible and Measurable Acceptance Criteria of this standard. Assemblies not
conforming to these criteria must be repaired or scrapped. The identified process adjustment criteria of this
standard do not cause the product to be nonconforming, and repair is not required.
3.4.2 Repair Procedures. Weld repair methods are shown in Appendix A. Arc welds or arc brazes must meet
applicable GMW14058 acceptance criteria. Arc welding should not be used for repair if the mating part is
thinner than 1.2 mm (arc brazing should be used instead.) Either arc brazing or arc welding may be used for
repairs when the mating part is 1.2 mm or thicker.
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Figure 1: Example of Torque Testing Welded Cages

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GMW16215

3.4.3 Repair Exceptions. An exception to specified product repair requirements may be permitted provided
there is documented review and approval by the responsible Product Engineer allowing the suspect product to
deviate from specification and conformance criteria.

4 Manufacturing Process
4.1 Process Control. The welding source is responsible for establishing practices and test methods to assure
that the criteria of this standard are met, and are consistent with GMW15563, Joining and Dispense Process
Control Procedure.
4.2 Process Adjustment Based on Weld Quality. The welding process shall show Evidence of Welding:

On all projections for nuts studs and cages with multiple projections.

Over the entire Weldable Length for fasteners with ring projections or parts with one or two long
projections.
The welding process shall be adjusted whenever either of these criteria is not met even though the welded
parts may not be discrepant.

5 Notes
5.1 Glossary.
Coined Projection: A raised protrusion formed in a solid part (such as a nut or the head of a stud) produced
by substantial mechanical force within a closed die such that the thickness of the protrusion is thicker than the
surrounding material.

Projection is Thicker than

surrounding Flange

Fastener (nut) with Coined

Projection

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Crack: A fracture type discontinuity characterized by a sharp tip and high ratio (length to width) of the opening
displacement on the exterior surface.
Embossed Projection: A raised protrusion formed in a sheet metal part such that there is basically no change
in metal thickness. (Welding of embossed projections is not covered in this standard.)

Sheet at Projection is not Thicker

than surrounding Sheet

Sheet with Embossed Projection

Evidence of Welding: Evidence of welding exists when a projection welded fastener that is destructively torn
from its mating part:

Tears a hole or crater in the mating part, or

Tears a projection from the fastener, or

Results in a post-weld projection height that is greater than the pre-welded projection height, or

Clear indication exists that material transfer has occurred.

Fastener: For the purpose of this standard, a fastener is a projection welded stud, nut, cage or other part.

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Gap: The distance between the base of the fastener and the mating part.

Gap
Fastener (nut)

Hole: A perforation in the spot weld that allows light to travel through the material from one exterior surface to
the opposing exterior surface of the weld.

Long Projections: Projections that are longer that 10 mm.

Set-Down: The process in which the projection is deformed under heat and pressure in order to clean both
surfaces and enable welding.
Spatter: Molten metal that has was expelled during the welding process and has later solidified.
Surface Eruption: Upsurge of the metal surface of the sheet metal directly behind the projections being
welded.
Surface Eruption on
back side of sheet

Fastener (nut)

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Torque Test: A proof test for welded cages. (Torque testing does not apply to weld fasteners.)

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Weldable Length: The total length of the projection that can be welded (measured at the base of the part with
the projection fully set down). The Weldable Length for ring projections is the circumference of the ring.

5.2 Acronyms, Abbreviations, and Symbols.

GMAB
Gas Metal Arc Brazing
GMAW
Gas Metal Arc Welding
5.3. Instructions. Inspection, measuring and test equipment to perform push-out load testing must be capable
of evaluating the specified load to an accuracy of 100 N. Parts being evaluated to the push-out load
requirements of this document are to be mounted in such a way as to ensure that the applied loads are
transferred through the welds of the joined parts. The push-out load must be applied perpendicular to the plane
of the attachment.

6 Coding System
This standard shall be referenced in other documents, drawings, etc., as follows:
GMW16215

7 Release and Revisions

This standard was originated in April 2009. It was first approved by the GM Global Weld Council in September
2010. It was first published in September 2010.
Issue

Publication Date

SEP 2010

Description (Organization)
Initial publication.

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Weldable Length

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GMW16215

Appendix A: Projection Welded Nut, Stud, Cage and Other Part Repair
Table A1: Method of Repair for Projection Welded Nut, Stud, Cage, and Other
Description

Reference

Method of Repair

Missing fastener
(part not painted)

Fastener is not
installed.

3.1.1

Reprocess part and install projection welded fastener, or install

fastener with GMAW/GMAB fillet welds/brazes on two opposite
sides for square head fasteners, or with fillet welds/brazes on
two pair of opposite faces for hexagonal headed fasteners, or
with two fillet welds/brazes, or two fillet welds/brazes covering
90 circumference opposite each other for round headed
fasteners, or with two 15 mm long fillet welds/brazes on
opposite sides of cages, or weld/braze all around for parts with
ring projections or long projections. (See Note 1 and Note 2.)

Missing fastener
(part is painted)

Fastener is not
installed.

3.1.1

Prepare faster location by grinding to remove paint. Install

fastener with GMAW/GMAB fillet welds/brazes on two opposite
sides for square head fasteners, or with fillet welds/brazes on
two pair of opposite faces for hexagonal headed fasteners, or
with two fillet welds/brazes, or two fillet welds/brazes covering
90 circumference opposite each other for round headed
fasteners, or with two 15 mm long fillet welds/brazes on
opposite sides of cages, or weld/braze all around for parts with
ring projections or long projections. Re-paint after repair. (See
Note 1 and Note 2.)

Mislocated fastener

The fastener is
located outside the
position tolerance.

3.1.1

Remove the mislocated fastener and grid as necessary to

restore the mating surface. Follow appropriate repair for
missing fastener.

Cracks or holes
(part not painted)

Crack or hole is
present.

3.2.1
3.2.2

GMAW or GMAB so that the discrepant condition is no longer

present. (See Note 1 and Note 2.)

Cracks or holes
(part is painted)

Crack or hole is
present.

3.2.1
3.2.2

Prepare faster location by grinding to remove paint. GMAW or

GMAB so that the discrepant condition is no longer present.
Re-paint after repair. (See Note 1 and Note 2.)

Weld spatter

Fastener has
spatter in or on its
threads.

3.2.3

When spatter impedes subsequent assembly, clean threads

with wire brush (for studs) or with a tap (for nuts).

Insufficient weld
quality or
inadequate weld
quality
(part not painted)

Weld quality is
insufficient.

3.3.1
3.3.2
3.3.3
3.3.4

Add GMAW/GMAB fillet welds/brazes on two opposite sides

for square head fasteners, or with fillet welds/brazes on two
pair of opposite faces for hexagonal headed fasteners, or with
two fillet welds/brazes, or two fillet welds/brazes covering 90
circumference opposite each other for round headed
fasteners, or with two 15 mm long fillet welds/brazes on
opposite sides of cages, or weld/braze all around for parts with
ring projections or long projections. (See Note 1 and Note 2.)

Insufficient weld
quality or
inadequate weld
quality
(part is painted)

Weld quality is
insufficient.

3.3.1
3.3.2
3.3.3
3.3.4

Prepare faster location by grinding to remove paint.

Add GMAW/GMAB fillet welds/brazes on two opposite sides
for square head fasteners, or with fillet welds/brazes on two
pair of opposite faces for hexagonal headed fasteners, or with
two fillet welds/brazes, or two fillet welds/brazes covering 90
circumference opposite each other for round headed
fasteners, or with two 15 mm long fillet welds/brazes on
opposite sides of cages, or weld/braze all around for parts with
ring projections or long projections. Re-paint after repair. (See
Note 1 and Note 2.)

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Discrepant
Condition

Note 1: GMAW/GMAB repair welds/brazes must meet GMW14058 acceptance criteria.

Note 2: GMAW should not be used when mating part is thinner than 1.2 mm.
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