Weld Nuts

Testing of the Welded Connection

Prepared: on: Issue: 0 No.
Schmidt, Schniedemeier, Heinrichs 01.Febr 2005 Substitute for: A_QM_012 Anl2 A_PG_029_Anl_11

Correction note on this issue: adaptation to the worldwide VA Welding, no changes in contents compared to the old version

Purpose of the guideline

• With this guideline it is guaranteed, that there are the same rules for processing weld nuts, incoming goods
inspection of parts with weld nuts and quality pre-planning. For purchase parts with weld nuts, compliance with
this guideline has to be observed.
Determination of objectives
• The requirements to the mechanical properties of the connections as well as the minimum values of the test
forces are determined in the respective drawings, standards and specifications.
To be able to detect negative tendencies and influences on the components in time, the following tests have to
be applied targeted.
The importance of the welding parameters power, time and pressure are expressly pointed out. The
requirements of this guideline also have to be transferred to external manufacturing (purchase parts, extended
workbench).
Should there be no customer defaults, works standard VW 604 32 is applied.

Test methods
• For supervision of the requirements to the welded connection, mainly the following tests are applied.

Torque test
• The welded connection between the weld nuts and sheets is tested by means of torque. The minimum torques
according to the respective specifications (e.g. VW 604 32) only apply to bond strength of the welded
connection and are designed that way, that the weld nuts must not loosen in case of a break of the tread
connections.
Screwing test
• Simulation of the screw connection as planned
• Here the screw connection as planned is simulated and the screwing flow is represented by means of a
diagram torque/torsion angle.
• Substitute test
• As an alternative, a statement can be made with regard to yield point and (max.) moment by means of an
electronic torque wrench.
• Series test
• As a series test, the connection can also be tested by means of a torque wrench with slave pointer or up to
the break of the bolt (quality according to drawing default).
These tests in general have to be dealt with as destructive tests, i.e. the components have to be scrapped.

Accurate dimensions of the thread

• To be able to detect upsetting or other defective development in time, accurate dimensions have to be tested
by means of a thread mandril gage (Attention: observe thread tolerance!)
Hardness test
• The hardness test is a substitute test for the strength test of the welded nut. The test is normally executed at
the cut nut in the core as well as at the ground front face.
Note: the smaller the test load, the better the section quality has to be.

Test load test

• Here an “original bolt” is screwed into the nut to be tested and loaded with axial pressure with approx. 70 % of
the required test load (hold time 15 sec.). After relief, the bolt must be movable by hand. This procedure is
repeated with respective 10 % load increases, max. up to loading conditions of 120 %. For the loading cases >
100 %, introduction of movability with a screw tool is admissible up to 1/2 revolution.

Head tractive force test

• Adhesion between weld nut and component is tested by axial tensile load.
• In case of missing facilities or as substitute test, respectively (e.g. as WE test), the “hammer blow test” can be
used. For that, tensile stress is created by means of a hammer blow to a screwed-in "standard bolt". In case of
a “not ok” result, however, the test has to be executed by means of axial tensile load. For that, at most one of
the welding projections must show no crystalline break-out.

VA_D_Anlageblätter_Rev1.dot / 12.2002 Printouts are not subject to changes. Page: 1 of 2

File: A_PG_029_Anl_11_gb.doc
The VA has to be checked for topicality before use!
 Weld Nuts
Testing of the Welded Connection
Prepared: on: Issue: 0 No.
Schmidt, Schniedemeier, Heinrichs 01.Febr 2005 Substitute for: A_QM_012 Anl2 A_PG_029_Anl_11
Test force test
• With this test the strength of the nut in axial direction is determined. In cases of doubt it is applied as
arbitration. (also see DIN 267 T4 and DIN ISO 898 T2).

Shop method
• The weld nut is torn out of its connection vertically to the sheet or knocked off. For that, at most one of the
welding projections must show no crystalline break-out. The shop test is no perfect substitute for the above
tests.

Summary of the test procedures

Key defaults:
Test procedures Interval series Comment
-----------------------------------------------------------------------------------------------
Torque test 1/2 h N, P, I, R
Screwing test 1/shift N, P, I, R
Accurate dimensions of the thread 1/2 h. N, P, I, R
Hardness test N, P, I, R
Test load test R
Head tractive force test 1/month N, P, I, R
Test force test R

N = for new start, plant changes P = after parameter changes

I = after repairs R = for complaints (internal and external)
• The above testing frequencies are minimum requirements, which depending on process safety may be
tightened.

Verification of the objectives

• Verification of the objective fulfillment takes place by entry into the rule cards.

Deviation from objectives and corrective measures

• The procedure is described in VA “Reaction in case of ‘not ok’ test results", if required, measure plans have to
be prepared.

Documentation and archiving

• Documentation takes place on the rule cards, in error messages or in the measure plans.
Archiving takes place according to the regulations of the respective procedure instruction.

Personnel qualification
• The employees executing the activities and tests must be qualified that way, that responsible and proper
execution are guaranteed.

Applicable documents
• Legal regulations (- in particular product liability law) and customer instructions as well as guidelines and sets
of rules agreed in the project and the current product drawing.

VA_D_Anlageblätter_Rev1.dot / 12.2002 Printouts are not subject to changes. Page: 2 of 2

File: A_PG_029_Anl_11_gb.doc
The VA has to be checked for topicality before use!