Contact US

Log In

Come Join Us!

Are you an
Engineering professional?
Join Eng-Tips Forums!
  • Talk With Other Members
  • Be Notified Of Responses
    To Your Posts
  • Keyword Search
  • One-Click Access To Your
    Favorite Forums
  • Automated Signatures
    On Your Posts
  • Best Of All, It's Free!

*Eng-Tips's functionality depends on members receiving e-mail. By joining you are opting in to receive e-mail.

Posting Guidelines

Promoting, selling, recruiting, coursework and thesis posting is forbidden.

Students Click Here

Projection Welding with HSLA Steel

Projection Welding with HSLA Steel

Projection Welding with HSLA Steel

I am working on an automotive application involving welding a 7/16" projection weld nut to 1.8mm High Strength Low Alloy Steel. (SP253-590) I am having a difficult time developing optimum weld parameters to maintain the specified push out requirement. Has anyone done a study on projection welding with HSLA steel or have any suggestions?

RE: Projection Welding with HSLA Steel

What type of projection weld nut are you using?  Hex with 3 projections?  Other?  The best standard that I have seen on this subject is DaimlerChrysler Process Standard PS-1804 WELD NUTS - PROJECTION WELDING.  For the above mentioned weld nut, the following parameters apply:

Electrode force = 8900 N (2000 lbs)
Weld time = 16-20 cycles
Current = 23-25 K-amps

The required push-off force should be 18680 N (4200 lbs) and the Torque to failure should be 271 Nm (2400 in-lbs).  Other parameters are given for different combinations of weld nut geometry and sheet metal thickness.  You can obtain this standard from AutoWeb using the following link:


RE: Projection Welding with HSLA Steel

The 7/16" nut is square with (4) projections. The projection height is 1.3mm

Does the DC PS-1804 cover different metals Low Carbon, Galanized, Galvanealed, HSLA.....????

RE: Projection Welding with HSLA Steel


I recommend that you stop using the 4-projection square nut and replace it with a suitable 3-projection nut.  With 4-projection nuts, often one projection is significantly out of plane.  The variable weld cross-section causes welding problems which in turn causes low mechanical properties.  An analogy is a table with 4 legs - three legs define a plane with the floor, and one of the legs is out of plane and requires a sugar packet to prevent table movement.

RE: Projection Welding with HSLA Steel

The DC standard acknowledges that different substrates (HSLA, galvanized, etc.) are used, but does not necessarily have different performance requirements or weld parameters.

RE: Projection Welding with HSLA Steel

Hi Robo
Is your material a "coated material" ie galvaneal, galvanized, hot dip ? as the thickness of coating can have a significant effect on weld integrity.

Red Flag This Post

Please let us know here why this post is inappropriate. Reasons such as off-topic, duplicates, flames, illegal, vulgar, or students posting their homework.

Red Flag Submitted

Thank you for helping keep Eng-Tips Forums free from inappropriate posts.
The Eng-Tips staff will check this out and take appropriate action.

Reply To This Thread

Posting in the Eng-Tips forums is a member-only feature.

Click Here to join Eng-Tips and talk with other members! Already a Member? Login


Close Box

Join Eng-Tips® Today!

Join your peers on the Internet's largest technical engineering professional community.
It's easy to join and it's free.

Here's Why Members Love Eng-Tips Forums:

Register now while it's still free!

Already a member? Close this window and log in.

Join Us             Close