Group standard PV 6727

Issue 2018-06
Class. No.: 04815

Descriptors: CDW, capacitor discharge projection welding, capacitor discharge welding, resistance projection
welding, steel, weld bolt, weld element, weld nut, weld stud, welded joint, welding

Resistance Projection Welding of Steel Materials

Testing and Evaluation of Welded Joints

Preface
Partially replaces VW 60560: 2015-11
NOTE 1: The new issue of this standard replaces the contents of VW 60560: 2015-11 regarding
resistance projection welding for weld elements.

Previous issues
VW 60560: 2003-06, 2004-11, 2010-10, 2015-11; PV 6727: 2009-02

Changes
The following changes have been made to PV 6727: 2009-02:
– Title changed and area of application expanded: resistance projection welding of weld ele‐
ments and on wire-like components added
– Contents for weld elements from VW 60560: 2015-11 integrated into this standard
– Table 2: Completely revised
– Table 3: Values for elongated projection omitted
– Table 4: Completely revised
– Figure 3: Revised
– Section 5.4: Expanded
– Table 8: Revised
– Section 6: Revised
– Specifications for usability omitted and section 7 updated
– Appendix A: Expanded to include rework
– Appendix B and Appendix C added

Always use the latest version of this standard.

This electronically generated standard is authentic and valid without signature. Page 1 of 31
The English translation is believed to be accurate. In case of discrepancies, the German version controls.

Technical responsibility The Standards department

PMT-F/T Ewgeni Agibalow Tel.: +49 5361 91 98681 K-ILI/5 Tim Hofmann K-ILI
EXDV/3 Matthias Jesser Tel.: +49 5361 9 48810 Tel.: +49 5361 9 27995 Uwe Wiesner

All rights reserved. No part of this document may be provided to third parties or reproduced without the prior consent of one of the Volkswagen Group’s Standards departments.
© Volkswagen Aktiengesellschaft VWNORM-2018-02
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Contents
Page
1 Scope ......................................................................................................................... 3
2 Definitions .................................................................................................................. 3
3 Symbols and abbreviations ........................................................................................ 4
4 Requirements ............................................................................................................. 5
4.1 General information .................................................................................................... 5
4.2 Welded joints of weld elements and sheet metals (type A) ........................................ 5
4.3 Welded joint for sheet metals (type B) ....................................................................... 5
4.4 Welded joint for wire-like components and sheet metals (type C) ............................. 5
5 Quality characteristics ................................................................................................ 6
5.1 General information .................................................................................................... 6
5.2 External quality characteristics ................................................................................... 6
5.3 Internal quality characteristics .................................................................................... 9
5.4 Strength characteristics ............................................................................................ 18
6 Quality characteristic testing .................................................................................... 20
6.1 General information .................................................................................................. 20
6.2 Testing of external quality characteristics ................................................................ 21
6.3 Testing of internal quality characteristics ................................................................. 21
6.4 Testing of strength characteristics ........................................................................... 22
7 Overall evaluation of the joint ................................................................................... 27
8 Applicable documents .............................................................................................. 28
9 Bibliography ............................................................................................................. 28
Appendix A Rework ..................................................................................................................... 29
A.1 General information .................................................................................................. 29
A.2 Gas-shielded arc welding ......................................................................................... 29
A.3 Machine follow-up on weld spots ............................................................................. 29
Appendix B Notes on capacitor discharge projection welding ..................................................... 30
B.1 General information .................................................................................................. 30
B.2 Requirements for welded joints ................................................................................ 30
B.3 Welding solid projections ......................................................................................... 30
Appendix C Further information regarding the testing of quality characteristics .......................... 31
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1 Scope
This standard defines the testing and evaluation of resistance projection welding joints carried out
– between a steel sheet metal and a weld element1),
– between two steel sheet metals, or
– between a steel sheet metal and a wire-like component,
see table 1.

Table 1 – Types of resistance projection welding joints

Components combination Joint properties Field of applica‐
Type Steel sheet metal Joint counterpart tion

Component Property
Standard thread range:
M4 to M12
General infor‐
A t > 0.5 mm Weld element Fine-pitch thread range: —
mation
M12 × 1.5 to M16 × 1.5
7/16 – 20 UNF
Total sheet
Steel sheet metal Thickness range: metal Body manufac‐
B 0.7 mm ≤ t ≤ 3.0 mm
with weld projection 0.7 mm ≤ t ≤ 3.0 mm thickness: ture
≤ 6 mm
0.5 mm ≤ t ≤ 4.0 mm Body manufac‐
C Wire-like component — —
ture

Generally valid limits are established in order to ensure uniform production quality for projection
welded joints. The standard defines permissible deviations that generally provide sufficient strength
properties for the use cases.
NOTE 2: This standard is used in sample inspections, acceptance inspections, and monitoring
conformity of production inspections and provides information for determining reworking measures.
NOTE 3: For deviations in weld shapes, VW 01103 can be used accordingly. VW 01103 also de‐
scribes the resistance projection welding process.
NOTE 4: This standard is applicable for production or multi-use parts with three or more projec‐
tions or circular projections.

2 Definitions
The following definitions apply to the application of this document.

Temporary resistance projection welding

Welded joint with reduced quality requirements, identified in the drawing with quality level D

Weld element
Fastener to be welded, e.g., weld bolt, weld nut, nut cage

1) Standard weld elements include weld bolts (e.g., as per DIN 34817 [2], VW 60011 [8]), square weld nuts (e.g., as per VW 60442
[11], VW 60449 [12], VW 60432 [9]), hexagon weld nuts (e.g., as per DIN 929 [1], with flange as per VW 60455 [13] ), round weld
nuts, and speed nuts (e.g., as per VW 60440 [10]).
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3 Symbols and abbreviations

bB Width of the projection
bn Width of the weld nugget
bp Width of the raised welding residue
dk Head diameter
dn Weld nugget diameter
dn, min Minimum weld nugget diameter
dnr Weld nugget diameter of the residual cross section
dp Raised welding residue diameter
dp1 Major axis of the raised welding residue or the crystalline fracture surface
dp2 Minor axis of the raised welding residue or the crystalline fracture surface
dS Support diameter
dw Weld spot diameter
dw, min Minimum weld spot diameter
d1 Projection diameter
e Width across corners
FK Cross-tension force
FK, min Minimum cross-tension force
FK, mean Mean cross-tension force
FKi, min Interpolated minimum cross-tension force
Fmax Maximum tensile force to apply in the shear test
Fmin Required tensile force to be applied
FS Shear force
FS, min Minimum shear force
FS, mean Mean shear force
FV Assembly preload force
h Length of an imperfection, or length of several overlapping imperfections
L Crack length
lB Length of the projection
ln Length of the weld nugget
loV Weld length, no connection
lp Length of the raised welding residue
MT Tightening torque
Mi, min Interpolated minimum tightening torque
Mmin Minimum tightening torque
p Weld nugget penetration
s Standard deviation
t Sheet metal thickness
Δl Difference in the weld lengths l1 and l2 for double-sided projection welding

A Projection welded joints of sheet metal and weld elements, done with solid
projections
B Projection welded joints of two sheet metals, done with stamped round or
elongated projections, or cut solid projections
C Projection welded joints of sheet metal and wire, done with natural solid
projections
COK Conditionally OK
OK Test passed
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PV 6727: 2018-06

NOK Not OK
PDM Product Description Manual
SGR Welded assembly
HAZ Heat-affected zone
ASSY Assembly

4 Requirements

4.1 General information

The released drawing is the basis for the evaluation of the welded joint.
NOTE 5: An entry in the drawing makes the application of this standard binding.
Requirements deviating from this standard are to be specified in the drawing and take precedence.
Additional measures required in order to fulfill specific quality requirements must be agreed upon
between the responsible parties at Planning, Design Engineering, and Quality Assurance.

4.2 Welded joints of weld elements and sheet metals (type A)

Requirements for the design, calculation, and process reliability are specified in VW 01103 and
VW 01110-1.

4.3 Welded joint for sheet metals (type B)

Requirements for the design, calculation, and process reliability are specified in VW 01103.

4.4 Welded joint for wire-like components and sheet metals (type C)
The following design requirements apply:
Difference in weld length for double-sided projection welding: Δl ≤ 5% or Δl ≤ 1.5 mm

Figure 1 – Difference in weld length for double-sided projection welding

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Difference Δl in weld lengths l1 and l2 for welding of double elongated projections in one process:
Δl ≤ 5% or Δl ≤ 1.5 mm

Figure 2 – Different weld lengths l1 and l2 when welding double elongated projections in one
process

5 Quality characteristics

5.1 General information

The joint quality is generally ensured with a predefined process window in the manufacturing facili‐
ty. Process monitoring of various parameters can be used to reduce the frequency of destructive
tests, depending on the level of process reliability involved. However, for confirmation purposes,
regular destructive tests are to be carried out (e.g., tightening torque tests) and the measured re‐
sults are to be documented. The testing intervals must be agreed upon between Planning, Quality
Assurance, and Production.
Production control, allowing for conclusions regarding the strength of welded joints, is normally
conducted by means of mechanical/technological testing (e.g., tensile tests).

5.2 External quality characteristics

Limits for exterior quality characteristics are specified in table 2.
 Table 2 – Specifications for external quality characteristics and evaluation
Test result
No. Characteristic Type Illustration Requirement/reliability
Possible findings Evaluation
2.1 Welded joint present A, B, C — Present Present OK
Not present NOK
2.2 Weld length C — ≥ 90% of target weld length ≥ 90% of target weld length OK
≥ 80% of target weld length COK
< 80% of target weld length NOK
2.3 Position A, B, C — As per drawing Position of the welded joint accord‐ OK
ing to drawing
Position of the welded joint not ac‐ NOK
cording to drawing
2.4 Surface cracka) A, C Not permissible Not present OK
Present NOK

1 Steel sheet metal

2 Solid bracket
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 Test result
No. Characteristic Type Illustration Requirement/reliability
Possible findings Evaluation
Page 8

2.5 Weld spatter B, C Permissible Not present OK

Present OK
Outside of the thread:
PV 6727: 2018-06

A Permissible Not present outside of the thread OK

Present outside of the thread OK
In the thread or thread runout:

1 Weld spatter Not permissible Not present in the thread or thread OK

runout NOK
Present in the thread or thread run‐
out

2.6 Marking B, C Permissible Not present OK

Present OK
Visible area:
Not permissible Not present OK
Present NOK

1 Marking

a) Surface cracks are not evaluated for type B.

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5.3 Internal quality characteristics

5.3.1 Welded joint type B

Limits for weld nugget and weld spot diameters for type B are specified in table 3.

Table 3 – Projection and joint dimensions for type B

Dimensions in millimeters
Weld projection Welded joint
Projection diameter/width Minimum weld nugget diameter Minimum weld spot diameter
d1 dn, min = 0.65 d1a)b) dw, min = 1.15 dn mina)c)
1.4 0.9 1.0
1.6 1.0 1.2
2.0 1.3 1.5
2.5 1.6 1.9
3.2 2.1 2.4
4.0 2.6 3.0
5.0 3.3 3.7
6.3 4.1 4.7
8.0 5.2 6.0
10.0 6.5 7.5

a) The formula is to be applied to unlisted projection diameters. The calculation dw, min = 1.15 dn, min is not generally permissible. Smaller
minimum weld spot diameters dw, min = dn, min are permissible only if they are verified by means of comparison measurements.
b) For elongated projections, the d1 must be replaced accordingly in the formula by lB (length of projection). For weld nugget geometry
in elongated projections, the following applies: ln ≥ 0.65 lB. In addition, bn ≥ bB applies (see also VW 01103).
c) For segmented projections that act like an individual projection (e.g., 3-spot VW projection), the spot weld shear diameters cannot
be measured individually due to the small clearances. In these cases, the total diameter must be measured and divided by the num‐
ber of projections.

5.3.2 Welded joint types B and C

Limits for internal quality characteristics are specified in table 4.
 Table 4 – Specifications for internal quality characteristics and evaluation
Test result
No. Characteristic Type Illustration/note Requirement/reliability
Page 10

Possible findings Evaluation

4.1 Length of the C — lp ≥ 90% of target weld length lp ≥ 90% of target weld length OK
torn out raised lp ≥ 80% of target weld length COK
PV 6727: 2018-06

welding resi‐ lp < 80% of target weld length NOK

due
B For elongated projections lp ≥ 0.65 lB lp ≥ 0.65 lB OK
lp < 0.65 lB NOK

4.2 Width of the B For elongated projections bp ≥ bB bp ≥ bB OK

torn out raised bp < bB NOK
welding resi‐
due
4.3 Weld spot di‐ B — dw ≥ dw, min dw ≥ dw, min OK
ameter dw < dw, min NOK
4.4 Fracture type
a) Plug failure B dw > dw, min dw ≥ dw, min OK
or tear failure dw < dw, min NOK
dp1 + dp2
dw =
2

See table 3
 Test result
No. Characteristic Type Illustration/note Requirement/reliability
Possible findings Evaluation
a) Plug failure C lp ≥ 90% of target weld length lp ≥ 90% of target weld length and OK
or tear failure loV ≤ 10%, but loV ≤ 5 mm at the weld
beginning or weld end
Not torn out/pulled out areas loV at the lp ≥ 90% of target weld length and OK
weld beginning or at the weld end per‐ loV ≤ 10%, but loV ≤ 6 mm at the weld
missible up to a maximum of 5 mm beginning or weld end

Sheet metal pulled or torn out of the part. Not torn out/pulled out areas loV at the lp ≥ 80% of target weld length and COK
weld beginning and at the weld end per‐ loV ≤ 20%, but loV ≤ 10 mm at the weld
missible up to a maximum of 6 mm in to‐ beginning or weld end
tal
lp ≥ 80% of target weld length and COK
ΣloV ≤ 20%, but ΣloV ≤ 12 mm at weld
beginning and weld end
lp ≥ 80% of target weld length NOK
lp1 = 27.0 mm lp ≥ 80% of target weld length and NOK
lp2 = 12 mm loV > 10 mm at the weld beginning or
loV = 15 mm weld end
lp ≥ 80% of target weld length and NOK
ΣloV > 12 mm at the weld beginning
and weld end
loV within the weld (not at the weld be‐ NOK
ginning or weld end)
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 Test result
No. Characteristic Type Illustration/note Requirement/reliability
Possible findings Evaluation
Page 12

b) Interfacial B 100% of the surface is crystalline and 100% of the surface is crystalline and OK
failure dw ≥ dw, min, dw ≥ dw, min
see table 3 < 100% of the surface is crystalline NOK
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and/or dw < dw, min

C Not permissible Not present OK

Present NOK

c) Hybrid fail‐ B Torn out and crystalline portion ≥ dw, min, Torn out and crystalline portion OK
ure see table 3 ≥ dw, min
Torn out and crystalline portion NOK
< dw, min

C — Not permissible Not present OK

Present NOK
d) Fracture in C Permissible Present OK
the base ma‐ Not present OK
terial

Example: bracket
 Test result
No. Characteristic Type Illustration/note Requirement/reliability
Possible findings Evaluation
4.5 Weld nugget B dn ≥ dn, min, dn ≥ dn, min OK
diameter see table 3 dn < dn, min NOK

4.6 Weld nugget B For straight elongated projections ln ≥ 0.65 lB ln ≥ 0.65 lB OK

length ln < 0.65 lB NOK

4.7 Weld nugget B For straight elongated projections bn ≥ bB bn ≥ bB OK

width bn < bB NOK

4.8 Weld nugget B For t ≥ 1 mm:

weld p ≥ 0.2 mm p ≥ 0.2 mm OK
penetration 0.1 mm ≤ p < 0.2 mm COK
p < 0.1 mm NOK
For t < 1 mm:
p ≥ 0.1 mm p ≥ 0.1 mm OK
p < 0.1 mm NOK
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 Test result
No. Characteristic Type Illustration/note Requirement/reliability
Possible findings Evaluation
Page 14

4.9 Cracks
a) Crack within B Permissible in center of weld nugget Present OK
the weld nug‐ Not present OK
get
PV 6727: 2018-06

b) Crack in the B Not permissible Not present OK

edge areaa) of Present NOK
the weld nug‐ Temporary resistance projection welding:
get
Permissible Not present OK
Present OK
c) Crack in the B Not permissible Not present OK
HAZ, at the Present NOK
joining plane Temporary resistance projection welding:
L ≤ 0.2 tmin L ≤ 0.2 tmin OK
L > 0.2 tmin NOK

d) Crack in the B Complete crack not permissible Not present OK

HAZ, on the Present, but without complete crack OK
electrode side, Complete crack
in the center NOK

1 Projection reshaped, no cracks (OK)

2 Crack in edge area (NOK), see characteris‐
tic 4.9 b)
 Test result
No. Characteristic Type Illustration/note Requirement/reliability
Possible findings Evaluation
d) Crack in the B L ≤ 0.2 tmin and L ≤ 150 µm L ≤ 0.2 tmin and L ≤ 150 µm OK
HAZ, on the L ≤ 0.2 tmin, but L > 150 µm COK
electrode side, L > 0.2 tmin NOK
on the edge
Temporary resistance projection welding:
area
Permissible Not present OK
Present OK
f) Crack in the B Not permissible Not present OK
HAZ, on the Present NOK
electrode side, Temporary resistance projection welding:
outside of the
L ≤ 0.2 tmin L ≤ 0.2 tmin OK
edge area
L > 0.2 tmin NOK

g) Crack in B Not permissible Not present OK

base material Present NOK
Temporary resistance projection welding:
L ≤ 0.2 tmin L ≤ 0.2 tmin OK
L > 0.2 tmin NOK
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 Test result
No. Characteristic Type Illustration/note Requirement/reliability
Possible findings Evaluation
Page 16

4.10 Pore B Solitary pore permissible if the pore is Not present OK

closed toward the weld nugget edge in Closed pore in the joining plane to‐ OK
the joining plane ward the weld nugget edge
PV 6727: 2018-06

Open pore in the joining plane toward NOK

the weld nugget edge
Pore (incl. wormhole, localized porosity) in
center and edge area of weld nugget Multiple pores permissible if the pores Not present OK
are closed toward the weld nugget edge Closed pores toward the weld nugget OK
in the joining plane and Σh ≤ 0.5 dn edge in the joining plane and Σh
≤ 0.5 dn
Closed pores toward the weld nugget NOK
edge in the joining plane, but
Σh > 0.5 dn
Open pore(s) in the joining plane to‐ NOK
ward the weld nugget edge
4.11 Filling flaw in B h ≤ 0.5 dn h ≤ 0.5 dn OK
weld nugget h > 0.5 dn NOK
center
Temporary resistance projection welding:
Permissible Not present OK
Present OK
 Test result
No. Characteristic Type Illustration/note Requirement/reliability
Possible findings Evaluation
4.12 Filling flaw in B Permissible if dnr ≥ dn, min, Not present OK
edge area of see table 3 dnr ≥ dn, min OK
the weld nug‐ dnr < dn, min NOK
get
Temporary resistance projection welding:
Permissible Not present OK
Present OK
4.13 Solid inclusion B Permissible Not present OK
Present OK

a) For a definition of the edge area, see figure 3.

PV 6727: 2018-06
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Page 18
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For a definition of the edge area and center of the weld nugget, see figure 3.

Legend
1 Edge area dn Weld nugget diameter
2 Center (width = 0.9 × dn) d1 Projection diameter
Figure 3 – Edge area and center of a weld nugget

5.4 Strength characteristics

5.4.1 Type A: Minimum cross-tension force and test tightening torque

The table 5 lists the strength characteristic limits for testing welded joints made with resistance pro‐
jection welding as per VW 01103.
The limits in table 5 apply to sheet metals made of steel with a thickness t of 0.5 mm to 4 mm.
Values must be interpolated linearly until the maximum specified sheet metal thickness t is reached
(see calculation example in table 5). In case of larger sheet metal thicknesses, the material must
be torn out from the joining plane; the requirements for the maximum specified sheet metal thick‐
ness t in table 5 apply.
The test carried out with the limits from table 5 is a destructive test. Parts that withstood the mini‐
mum tightening torque values as per table 5 are seen as damaged and are not to be used again.
If no fracture occurs in the welded joint in destructive testing during production after reaching the
minimum tightening torque as per table 5, then the test for thread sizes ≤ M6 at 2 times of the mini‐
mum tightening torque and for thread sizes > M6 at 1.5 times of the minimum tightening torque can
be stopped.
It must be ensured that welded joints that did not fail are discarded (i.e., they must not reach the
customer).
During production, the tightening torque test can be carried out as a function check with a test
tightening torque of 1.2 × MA2). Parts evaluated as OK can still be used.

2) MA as per VW 01126-1, table "Tightening torque MA and assembly preload values FM for socket head cap bolts" independent of
assembly tightening process, alternatively as per PDM.
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Table 5 – Type A: Limits for strength characteristics

Thread

M12 × 1.5; (M12)a)

Strength M14 × 1.5
M4 M5 M6 M8 M10
characteris‐ M16 × 1.5
tic 7/16 – 20 UNFb)
t in mm
0.5 1.25c) 0.5 1.25c) 0.5 1.75c) 0.75 3c) 1 3.5c) 1.5 3.5c)
FK, min N 1 200 2 000 1 200 2 000 1 400 2 500 2 300 4 000 4 500 8 000 4 800 8 000

Mmind) Nm 10 15 14 20 25 35 65 85 100 130 110 155

Interpolating minimum cross-tension force FKi, min and minimum tightening torque Mi, min for M6 thread and sheet metal
thickness ti = 1 mm:

(2 500 N − 1 400 N) × (1 mm − 0.5 mm)

(FK, min [1.75] – FK, min [0.5]) × (ti – tmin) FKi, min = + 1 400 N
FKi, min = + FK, min → 1.75 mm − 0.5 mm
tmax – tmin
= 1 840 N

(35 Nm – 25 Nm) × (1 mm – 0.5 mm)

(Mmin [1.75] – Mmin [0.5]) × (ti – tmin) Mi, min = + 25 Nm
Mi, min = + Mmin → 1.75 mm – 0.5 mm
tmax – tmin
= 29 Nm

a) Thread size M12 may only be used in special cases.

b) Permissible for seat belt fastening only.
c) For thicker sheet metals, the values specified in this column for FK, min and Mmin must be adhered to.
d) Applicable for weld nuts only.

5.4.2 Types B and C: Tensile strength

Limits for strength characteristics are specified in table 6 and table 7. The strength characteristic
values help designing the joints according to the load requirements.

Table 6 – Type B: Limits of the strength characteristics and evaluation

Test result
No. Characteristic Specification/illustration Limit/requirement
Possible findings Evaluation
6.1 Shear force See section 6.4.2.1. FS ≥ FS, min FS ≥ FS, min OK
FS < FS, min NOK

6.2 Cross-tension See section 6.4.2.2. FK ≥ FK, min FK ≥ FK, min OK

force FK < FK, min NOK

Table 7 – Type C: Limits of the strength characteristics and evaluation

Test result
No. Characteristic Illustration Limit/requirement
Possible findings Evaluation
7.1 Tensile force See section 6.4.1. Requirement for Fmin as per F ≥ Fmin OK
drawing F < Fmin NOK
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6 Quality characteristic testing

6.1 General information

For each quality characteristic, test methods can be selected using the matrix in table 8.

Table 8 – Quality characteristic testing

Test method

Tightening torque test

Hammer impact test
Dimensional check
Visual inspection

Ultrasound test
Quality characteristic

Thermography

Metallography

Tensile test
Chisel test

Peel test
Welded joint present X
quality characteristics

Weld length (X) (X)

External

Position X X
Surface crack X
Weld spatter X
Marking X
Length of the torn out raised welding X X
X
residue
Width of the torn out raised welding X X
X
residue
Weld spot diameter X X X
quality characteristics

Fracture type X X X X
Weld nugget diameter (X) X (X)
Internal

Weld nugget length (X) X (X)

Weld nugget width (X) X (X)
Weld nugget penetration X
Pores (X) X (X) (X) (X) (X)
Cracks X
Filling flaw X (X) (X) (X) (X)
Solid inclusion X
Tensile force X
characteristics
Strength

Shear force X
Cross-tension force X
Tightening torque X
X Test method suitable
(X) Test method conditionally suitable
 Page 21
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6.2 Testing of external quality characteristics

6.2.1 Visual inspection

In the visual inspection of the welded joint, the joint must be inspected with the naked eye (without
aids such as a magnifying glass or microscope).

6.2.2 Dimensional check

In the dimensional check, the quality characteristics must be checked in terms of dimensional ac‐
curacy with the use of a caliper or other suitable measuring device.

6.3 Testing of internal quality characteristics

6.3.1 Metallography
The metallographic test is a destructive test.
For the test, a metallographic microsection is to be produced whose section plane is in the center
of the weld nugget. The metal microstructure is made visible using suitable etching agents (e.g.,
2% solution of nitric acid in alcohol). The evaluation must be made on a microscope with a magnifi‐
cation of 40:1 (or greater) on the unetched microsection (for cracks) or on the etched microsection
(for the microstructure).
The metallographic inspection alone is not suitable to evaluate the internal quality characteristics of
a projection welded joint of the types A and C of solid parts (see VW 01103).
Strength tests must be carried out as per section 6.4.

6.3.2 Chisel test

The chisel test, e.g., according to DVS 2916-1, is a destructive test.
In the chisel test, an appropriately shaped chisel is driven between the welded sheet metals until
the projection welded joint is destroyed. In this process, the welded joint can pull out or the fracture
can occur in the joining plane (interfacial failure). Combinations of both these fracture types (so-
called hybrid failures) are also possible (see table 4).
For sheet metal thicknesses t > 2.0 mm, transverse microsections need to be made and the weld
nugget diameter needs to be determined. This applies, in particular, to high-strength and/or press-
quenched and tempered steels.
If multiple welded joints are tested in a series and are spaced close together, it is recommended to
test the weld spots individually. In this case, the welded joints must be separated, e.g., by cutting
them out with a saw.
When determining the weld spot diameter, a caliper is used to determine dp1 and dp2 of the raised
welding residue (2nd measurement offset by 90°) and the mean value is determined from the two
measurements. If a precise measurement in two directions is not possible, the measured diameter
must be used as dw.

6.3.3 Peel test

The peel test, see DVS 2916-1, is a destructive test.
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During the peel test, a suitable tool, e.g., a peel mandrel or pliers, is used to peel back the two
sheet metals, thereby destroying the projection welded joint. In this process, both the welded joint
and the part can tear.

6.3.4 Hammer impact test

The hammer impact test cannot be used to determine a technological characteristic value for
strength (such as shear strength or tightening torque).
The hammer impact test can help prepare the parts for evaluation of their fracture surfaces. The
hammer is used to open the parts, that is, to destroy the welded joints.
The component is to be firmly clamped in a vise and the solid part must be hit with a hammer with
a sufficient force so that the welded joint fails. The solid part either pulls out of the sheet metal, the
welded joint itself fails, or the solid part itself fractures.

6.3.5 Ultrasound test

During the ultrasound test (see DVS 2916-5 [4]), a probe that functions both as a transmitter and a
receiver is used to send a time-limited ultrasonic pulse into the weld structure. Subsequently, the
ultrasonic device switches immediately to the receiving mode and records the arriving echo se‐
quence. The ultrasonic pulse is largely reflected at the steel/air interface, but not if it moves
through an intact weld nugget. Information about the material thickness can be inferred from the
echos. Indirectly, this information can be used to determine whether or not a weld nugget is
present. Likewise, loose projection welded joints can be detected from the ultrasonic echo se‐
quence.

6.3.6 Thermography
Thermography is a test method in which flaws in the welded joint can be made visible by generat‐
ing temperature differences (e.g., stimulation by flash bulbs or cold air). Here, after stimulating the
welded joint, the temperature-time profile (heat flow) is evaluated, and the effect that different tem‐
perature-time profiles occur in the area of flaws is used to make these flaws visible.
NOTE 6: These visualizations can be used if proof is provided that the recorded parameters can
be related explicitly to a specific quality characteristic.

6.4 Testing of strength characteristics

6.4.1 Tensile testing on the part

Different types of loads can occur depending on the design of a part, e.g., shear force, cross-ten‐
sion, tensile peel, and torsion loads. The load direction to be tested is to be coordinated with the
Design Engineering department and/or be obtained from the drawing.
To evaluate the strength of a welded joint, a tensile test is to be carried out as per
DIN EN ISO 6892-1 [3]. The intent is to ensure that the welded joint is tested in a manner appropri‐
ate for the corresponding application. If the tensile test is to be carried out on the assembly (AS‐
SY), then the specifications in the drawing are to be taken into consideration.
The test for an ASSY displayed as an example in figure 4 with special specifications as per the
drawing describes a load case with axial tensile direction according to the level parallel to the pro‐
jection welded joints.
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The required force Fmin is applied according to figure 4. Similar testing methods are permissible if
they lead to the same result. Proof of this must be furnished by the user. The test must be run all
the way to failure.

Legend
F Tensile force to be applied
1 Weld
Figure 4 – Shear test using the backrest locking fastener welded assembly as an example

6.4.2 Tensile testing on specimens

6.4.2.1 Shear test

The shear test is a destructive test. An individual projection welded joint is tested in a tensile test
machine until the joint or the component fails. The tearing force required to do this is measured.
The test must simulate the actual load direction. Auxiliary fixtures may be necessary for this pur‐
pose.
If a load of this type cannot be simulated, an easy-to-reproduce load may be chosen according to
figure 5.
Specimen dimensions and procedure according to DIN EN ISO 14273.
At least five specimens are required for testing.
To determine the strength limits in table 6, at least five specimens must be tested. The strength
values must be determined from specimens of those series whose inner quality characteristics
(see section 5.3.2) have been evaluated with OK.
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FS, min is determined according to formula (1) from the mean value of five individual values:

FS, min = FS, mean − 2s (1)

Legend
1 Outer notch
Figure 5 – Shear test

6.4.2.2 Cross-tension test

The cross-tension test is a destructive test. Like the shear test, this test is conducted in a tensile
test machine, but the load is applied perpendicular to the sheet metal plane, see figure 6. The test
may be performed according to figure 5 in exceptional cases.
At least five specimens are required for testing.
To determine the strength limits in table 6, at least five specimens must be tested. The strength
values must be determined from specimens of those series whose inner quality characteristics
(see section 5.3.2) have been evaluated with OK.
FK, min is determined according to formula (2) from the mean value of five individual values:

FK, min = FK, mean − 2s (2)

NOTE 7: During the cross-tension test, 25% to 40% of the minimum shear force FS, min must be
achieved, according to the respective deformability.

Figure 6 – Cross-tension test

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6.4.3 Cross-tension test for joints with weld elements

Cross-tension force FK is applied as per figure 7 and figure 8. The test procedure is the procedure
for the test force test in DIN EN ISO 898-2. Similar test methods are permissible if they lead to the
same result. Proof of this must be furnished by the user.
The test must be run all the way to failure.

Legend
dk Head diameter
dS Support diameter
e Width across corners
FK Cross-tension force
FV Assembly preload force
1 Test part (e.g., weld nut as per VW 60449 [12])
2 Test part (e.g., weld bolt as per DIN 34817 [2])
3 Test tool

a
Depending on the weld element geometry, the following applies to the support diame‐
ter: dS = e + 3 mm or dS = dK + 3 mm.
b
For the support of the assembly preload force of weld elements, VW 01110-1 must be
observed.
Figure 7 – Test setup for a cross-tension test with the cross-tension force against the direction of
the assembly preload force exerted later on (schematic)
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Legend
dk Head diameter
dS Support diameter
FK Cross-tension force
FV Assembly preload force
1 Test part (e.g., weld bolt as per VW 60011 [8])
2 Nut (with width across corners e)

a
Depending on the weld element geometry, the following applies to the support diame‐
ter: dS = e + 3 mm.
b
The assembly preload force is usually supported by the screw head/stud bolt flange.
For the support of the assembly preload force, VW 01110-1 must be observed.
Figure 8 – Test setup for a cross-tension test with the cross-tension force in the direction of the
assembly preload force exerted later on (schematic)

6.4.4 Tightening torque test for joints with weld nuts

The strength of the welded joint with weld nuts must be tested with the minimum tightening torque.
If welded joints with weld nuts cannot be tested directly, it is permissible for the cross-tension test
to be conducted as an alternative.
The tightening torque must be applied with a suitable and calibrated test fixture. The maximum er‐
ror limit is 2% relative to the maximum value of the specified measuring range depending on the
dimensions.
When determining and defining the welding parameters, the test must be run all the way to failure.
Figure 9 provides a schematic diagram of the test setup.
For round weld nuts, the required minimum tightening torque may be tested using machined
wrench bearing surfaces specifically matched to the relevant sheet metal thickness.
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Legend
M Tightening torque
1 Torque wrench
2 Test part (e.g., weld nut as per VW 60449 [12])
Figure 9 – Test setup for tightening torque test (schematic)

7 Overall evaluation of the joint

The following system for evaluating a joint can be used and may be adapted to the particular vehi‐
cle if necessary.
– A projection welded joint is evaluated as OK if, of all the tested quality characteristics,
– no quality characteristic was evaluated as NOK and
– no quality characteristic was evaluated as COK.
– A projection welded joint is evaluated as COK if, of all the tested quality characteristics,
– no quality characteristic was evaluated as NOK and
– no more than one quality characteristic was evaluated as COK.
– A type A projection welded joint is evaluated as COK if, according to table 5,
– the minimum tightening torque is fulfilled but the cross-tension force is not, or
– the cross-tension force is fulfilled despite the minimum tightening torque not being fulfilled.
– A projection welded joint must be evaluated as NOK if, of all the tested quality characteristics,
– one quality characteristic was evaluated as NOK or
– two quality characteristics were evaluated as COK.

In the test during production, the part is evaluated as OK if an individual joint is evaluated as COK
and can be further used without rework. However, the process must be examined and, if necessa‐
ry, corrected. The evaluation "COK" must be regarded as a warning limit for "NOK" here.
If an individual joint location is evaluated as NOK, suitable steps must be taken to achieve an OK
evaluation. The batch manufactured in the meantime must be examined and reworked if necessa‐
ry.
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For the initial sample inspection of a part, this is evaluated with OK if all joints are evaluated with
OK.

8 Applicable documents
The following documents cited are necessary to the application of this document:
Some of the cited documents are translations from the German original. The translations of Ger‐
man terms in such documents may differ from those used in this standard, resulting in terminologi‐
cal inconsistency.
Standards whose titles are given in German may be available only in German. Editions in other
languages may be available from the institution issuing the standard.

VW 01103 Resistance Projection Welding; Design, Calculation, Process Reliability

VW 01110-1 Threaded Connections; Part 1: Design and Assembly Specifications
VW 01126-1 Tightening Torques for Threaded Connections; Part 1: Elastic Assembly
DIN EN ISO 14273 Resistance welding - Destructive testing of welds - Specimen dimen‐
sions and procedure for tensile shear testing resistance spot and em‐
bossed projection welds
DIN EN ISO 898-2 Mechanical properties of fasteners made of carbon steel and alloy steel -
Part 2: Nuts with specified property classes - Coarse thread and fine
pitch thread
DVS 2916-1 Testing of resistance welded joints - Destructive testing, quasi static

9 Bibliography
[1] DIN 929, Hexagon Weld Nuts
[2] DIN 34817, Weld Bolts with Metric Thread
[3] DIN EN ISO 6892-1, Metallic Materials – Tensile Testing – Part 1: Method of Test at
Room Temperature
[4] DVS 2916-5, Testing for Resistance Pressure Weld Joints – Non-Destructive Testing
[5] PS_3.1_999_1436_01, KAP_5_(Neu-)Teile bemustern ("Sample Inspection for (New)
Parts")
[6] PV 6717, Sheet Metal Panels (Deep-Drawn Parts) in Steel Body Manufacture; Evalua‐
tion, Rework, Inspection
[7] TL 4225, Alloyed Quenched and Tempered Steel for Press Quenching – Uncoated or
Pre-Coated; Materials Requirements for Semi-Finished Products and Components
[8] VW 60011, Weld Bolts with Metric Thread – Weld Projections on Head
[9] VW 60432, Square Weld Nuts; Low Profile
[10] VW 60440, Speed Nuts
[11] VW 60442, Square Weld Nuts; Tall Profile, Large Width Across Flats
[12] VW 60449, Square Weld Nuts; Tall Profile
[13] VW 60455, Hexagon Weld Nuts with Flange
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Appendix A (informative) Rework

A.1 General information

For rework options, see PV 6717 [6], or the applicable Finishing Manual or Rework Catalog.
Rework must conform to the quality requirements in this standard or to the valid standard for the
respective method.

A.2 Gas-shielded arc welding

If a welded joint is flawed, the part may be reworked with an additional joint using gas-shielded arc
welding.
This is primarily permissible when there is sufficient space and no other restrictions go against a
weld at the joint. If necessary, such an area must be declared or excluded for rework in the draw‐
ing.

A.3 Machine follow-up on weld spots

If a projection welded joint is faulty, part rework is possible by placing at least one new weld spot
next to the projection welded joint evaluated as NOK, separated by a sufficient distance (≥ 20 mm
or with a higher welding current).
This is primarily possible when, e.g., there is sufficient space at flanges and no other restrictions go
against a weld spot at another location. If necessary, such an area must be declared or excluded
for rework in the drawing.
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Appendix B (informative) Notes on capacitor discharge projection welding

B.1 General information

Resistance projection welding with a capacitor discharge can be used when welding wire-like solid
parts (ISOFIX anchorages or backrest strikers) with a natural solid projection to steel sheet metals.
For use cases referred to in this standard, the weld projection is created by the curve of the round
steel (natural solid projection), e.g., a wire. One or more projections can be welded at the same
time in a single processing step if the design and power of the welding equipment allow this.
For capacitor discharge projection welding, increased requirements for equipment and individual
part quality based on the state of the art must be taken into consideration.

B.2 Requirements for welded joints

If possible, type C projection welded joints addressed in this standard must only be subjected to
shear loads, since this is the type of load for which the largest forces can be transferred per joint.
Therefore, pure cross-tension or tensile peel loads must be avoided.
Figure B.1, Figure B.2, and Figure B.3 show for microsections of solid parts the typical occurrence
of inner irregularities of a projection welded joint for type C.

Figure B.1 – No weld nugget identified Figure B.2 – No weld nugget identified
(ISOFIX anchorage) (backrest striker)

Legend
1 Raised welding residue torn out of sheet metal
2 Backrest striker
Figure B.3 – Filling flaw

B.3 Welding solid projections

With solid projections (e.g., joints with weld nuts or ISOFIX anchorages) on sheet metals, there is
generally no typical, evaluable weld nugget. The welding material is surrounded by a heat-affected
zone.
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Appendix C (informative) Further information regarding the testing of quality characteristics

The test frequency, test scope, and test method are specified in a test plan and agreed upon be‐
tween Planning, Production, Quality Assurance, and, if necessary, Development.
Planning is responsible for creating the test plan. If necessary, detailed PVs are created by Pro‐
duction.
In sample inspections, all of the quality characteristics described in this standard are evaluated.
Following any optimizations, modifications of process parameters, etc., a release test must be con‐
ducted as per selected quality characteristics that are applied the same way as during production.
The quality characteristics used for production testing (in-line testing) are agreed upon and defined
by Planning, Production, Quality Assurance, and, if necessary, Design Engineering and Process
Engineering. These quality characteristics must be suitable in their entirety for monitoring the sta‐
bility of the manufacturing process and thus the quality of the joint.
The sample inspection of parts is performed as per Process Standard PS_3.1_999_1436_01 [5].
Following any optimizations, modifications of process parameters, etc., a release test must be con‐
ducted as per selected quality characteristics that are applied the same way as during production
testing.