GMW16215 PDF

Template For ENG STDS
WORLDWIDE
ENGINEERING Material Specification GMW16215
STANDARDS
Welding Acceptance Criteria and Repair Procedures: Resistance

Projection Welded Steel Nuts, Studs, Cages and Other Parts with
Solid Coined Projections
1 Introduction
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. This specification applies to resistance projection welded steel nuts, studs, cages, and other
parts with solid coined projections.
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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 Remarks. 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.
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.
© Copyright 2016 General Motors Company All Rights Reserved
March 2016 Page 1 of 7
Copyright General Motors Company Order Number: W1939481

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GM WORLDWIDE ENGINEERING STANDARDS Template For ENG STDS GMW16215
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.)
Table 1: Acceptable Quality Based on Projections with Evidence of Welding

Number of Number of Projections
Projections on the Part with Evidence of Welding
2 1
3 2
4 3
6 4
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
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).
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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. An example of torque testing welded
cages is shown in Figure 1.
Table 3: Torque for Testing Welded Cages

Minimum Torque
Weld Fastener Size
(N·m)
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

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Note: Shoulder Bolt is bottomed against Nut; Torque is applied in Tightening Direction. (Torque is not applied to outside walls of the cage.)
Figure 1: Example of Torque Testing Welded Cages
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 Table A1, 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.

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 Fastener (nut) with Coined

surrounding Flange 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

Sheet with Embossed Projection
than surrounding Sheet
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.

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

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.
Weldable Length
5.2 Acronyms, Abbreviations, and Symbols.

GMAB Gas Metal Arc Brazing
GMAW Gas Metal Arc Welding
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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 Description (Organization)
1 SEP 2010 Initial publication.
2 MAR 2016 Updated template and references per five year refresh. (Manufacturing
Engineering)

Appendix A: Projection Welded Nut, Stud, Cage and Other Part Repair
Table A1: Method of Repair for Projection Welded Nut, Stud, Cage, and Other
Discrepant
Description Reference Method of Repair
Condition
Missing fastener Fastener is not 3.1.1 Reprocess part and install projection welded fastener, or
(part not painted) installed. 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 Fastener is not 3.1.1 Prepare faster location by grinding to remove paint. Install
(part is painted) installed. 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 3.1.1 Remove the mislocated fastener and grid as necessary to
located outside the restore the mating surface. Follow appropriate repair for
position tolerance. missing fastener.
Cracks or holes Crack or hole is 3.2.1 GMAW or GMAB so that the discrepant condition is no longer
(part not painted) present. 3.2.2 present. (See Note 1 and Note 2.)
Cracks or holes Crack or hole is 3.2.1 Prepare faster location by grinding to remove paint. GMAW or
(part is painted) present. 3.2.2 GMAB so that the discrepant condition is no longer present.
Re-paint after repair. (See Note 1 and Note 2.)
Weld spatter Fastener has 3.2.3 When spatter impedes subsequent assembly, clean threads
spatter in or on its with wire brush (for studs) or with a tap (for nuts).
threads.
Insufficient weld Weld quality is 3.3.1 Add GMAW/GMAB fillet welds/brazes on two opposite sides
quality or insufficient. 3.3.2 for square head fasteners, or with fillet welds/brazes on two
inadequate weld 3.3.3 pair of opposite faces for hexagonal headed fasteners, or with
quality 3.3.4 two fillet welds/brazes, or two fillet welds/brazes covering 90°
(part not painted) 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 Weld quality is 3.3.1 Prepare faster location by grinding to remove paint.
quality or insufficient. 3.3.2 Add GMAW/GMAB fillet welds/brazes on two opposite sides
inadequate weld 3.3.3 for square head fasteners, or with fillet welds/brazes on two
quality 3.3.4 pair of opposite faces for hexagonal headed fasteners, or with
(part is painted) 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.)
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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Template For ENG STDS

Welding Acceptance Criteria and Repair Procedures: Resistance

March 2016 Page 1 of 7

Copyright General Motors Company Order Number: W1939481

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

Table 2: Acceptable Quality Based on Push-Off Force

© Copyright 2016 General Motors Company All Rights Reserved

March 2016 Page 2 of 7

Copyright General Motors Company Order Number: W1939481

Table 3: Torque for Testing Welded Cages

Sheet Metal Part

3.4 Disposition/Repair Procedure.

© Copyright 2016 General Motors Company All Rights Reserved

March 2016 Page 3 of 7

Copyright General Motors Company Order Number: W1939481

Projection is Thicker than Fastener (nut) with Coined

Sheet at Projection is not Thicker

© Copyright 2016 General Motors Company All Rights Reserved

March 2016 Page 4 of 7

Copyright General Motors Company Order Number: W1939481

Long Projections: Projections that are longer that 10 mm.

© Copyright 2016 General Motors Company All Rights Reserved

March 2016 Page 5 of 7

Copyright General Motors Company Order Number: W1939481

5.2 Acronyms, Abbreviations, and Symbols.

7 Release and Revisions

© Copyright 2016 General Motors Company All Rights Reserved

March 2016 Page 6 of 7

Copyright General Motors Company Order Number: W1939481

© Copyright 2016 General Motors Company All Rights Reserved

March 2016 Page 7 of 7

Copyright General Motors Company Order Number: W1939481

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