TM-2508 Rev 3 Weld Stud and Nuts-Steel

TM-2508
Weld Studs and Nuts - Steel

PROCESS SPECIFICATION | VERSION 03
0 Overview & Guidance

0.1 Laws. This specification shall never supersede applicable laws and regulations.
0.2 Language. Only the English language version of this text shall be binding.
0.3 Process Accreditation. All testing required by this specification must be conducted by a laboratory
accredited to ISO/IEC 17025 or registered to ISO/TS 16949 by an established third-party auditor.
0.4 Standard Obsolescence. It is the responsibility of the supplier to ensure that the most current
versions of all cited standards are employed.
0.5 Initial Source Approval. Delivery of production goods shall not be accepted until representative initial
production samples have been verified for compliance to this specification by Tesla Engineering.
0.6 Equivalency. Welded assemblies approved and purchased to this specification must be equivalent
in every respect to the initial samples verified and approved by Tesla Engineering. The right to
characterize joints at any time to ensure equivalency is reserved.
0.7 Change Reporting. The supplier is exclusively responsible for reporting all process changes not
explicitly allowable per this specification to Tesla Engineering. Welds and assemblies must be retested
as if for initial release unless agreed otherwise.
0.8 Quality Control. Test types, frequency and sample size for quality control must meet the
requirements defined in this document and be documented in the suppliers manufacturing control plan,
which shall be approved by Tesla Quality and Engineering.
0.9 Part Validation. Material suitability for service in a particular application may only be confirmed by
component-, system-, or vehicle-level testing. It is the responsibility of the release engineer to outline
part performance requirements in a design verification plan or related specification.
0.10 Drawing Precedence. In case of conflict, the requirements listed on the engineering part drawing
or model based definition shall take precedence over the terms and conditions of this specification.
0.11 IMDS Submission. All materials, components and processes used to produce parts under this
specification and delivered to Tesla Motors, or to be part of products delivered to Tesla Motors as part
of the assembled vehicle, must be registered to the International Material Data System prior to being
supplied for production usage.
1 Scope
The scope of this specification covers the Manufacturing and Quality requirements for welded fasteners,
which includes steel nuts and studs, welded by drawn arc and projection. This specification applies to
welded fasteners produced internally by Tesla as well as those sourced to suppliers. Specific
requirements for the fasteners, and substrate materials, are controlled via other Tesla Material
Specifications.
Printed copies are uncontrolled. Controlled documents reside electronically. Individuals in possession of an uncontrolled copy are
responsible for ensuring that they are using the latest revision of this document.
© 2014 Tesla Motors, Inc. Proprietary and confidential.
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TM-2508 TESLA MOTORS STANDARD
version 03 Process Specification: Welded Studs and Nuts - Steel
2 References
WA 950 Material Requirements and Mechanical Properties of Bolts, Studs, and Bolt & Washer
Assemblies.
WZ 100 Steel Metric Threaded Fasteners Torque/Clamping Force Performance
WE 505 Weld Nut - Hexagon Flange – Proof Load 10 Capability Category 250.020
WE 960 Material and Performance Requirements of Weld Nuts
WA 960 Material and Performance Requirements of Weld Bolts
GMW14056 Weld Acceptance Criteria and Repair Procedures Draw-Arc Welded Automotive Studs,
Nuts and Brackets
GMW16215 Welding Acceptance Criteria and Repair Procedures: Resistance Projection Welded Steel
Nuts, Studs, Cages and Other Parts with Solid Coined Projections
ISO 14555 Welding – Arc stud welding of metallic materials
ISO 898/1 Mechanical properties of fasteners made of carbon steel and alloy steel – Part 1: bolts,
screws and studs with specified property classes – coarse thread and fine pitch thread.
3 Definitions
Crack: A discontinuity characterized by a sharp tip and high aspect ratio of the opening on the exposed
surface.
Fusion: The melting together of a fastener and the base metal to produce a weld.
Eruption: Material that flows around and/or above the thread of the stud as a result of the welding
process.
Spatter: Weld expulsion metal that remains attached to adjacent surfaces.
4 Nomenclature
4.1 The following nomenclature shall be used to define welded fasteners on engineering drawings to
identify the requirements of this specification relevant to those joints.
[Fastener Type]-[Fastener Size]-[Weld Process]-[Material]-[Substrate Thickness]
4.2 [Fastener Type] refers to the joining process. The fastener types covered by this specification are:
[Stud] Weld Stud
[H-Nut] High Strength Hex Flange Weld Nut
[S-Nut] Low Strength Square Flange Weld Nut
Requirements for the fasteners are defined on the engineering drawings for each respective
fastener part number. Fastener part numbers shall be specified on the assembly level
engineering dataset or drawing to be utilized.
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4.3 [Fastener Size] identifies the size of fastener being utilized. This specification covers fastener sizes
from [M5] to [M12].
4.4 [Weld Process] identifies the welding method used to attach the fastener to the substrate. This
specification covers the following welding methods:
[Arc] Drawn Arc Welding
[Projection] Resistance Projection, or Capacitive Discharge, Welding
4.5 [Material] defines the substrate material the fastener is welded to.
[FeC] all steel alloys, and coatings, used by Tesla Motors.
Requirements for the substrate materials are defined within their respective material
specifications. The material specification shall be identified on the part/assembly engineering
dataset and/or drawing.
5 Requirements
This section defines the Non-Destructive and Destructive requirements and acceptance criteria for
Welded Fasteners produced to this specification, which are applicable to Equipment and Weld Schedule
Qualification as well as Routine Production Inspections outlined in subsequent sections of this
specification.
5.1 Non-Destructive. Non-destructive evaluations are performed as a part of process qualification as

well as in serial production for quality control purposes.
5.1.1 Visual. Visual inspection, without magnification, shall be used to evaluate the surface quality of
welded fasteners per Table 1.
Table 1: VISUAL REQUIREMENTS
Requirement Grade A
Spatter None on Threads
Acceptable Provided it Doesn’t Interfere

Eruption with Mating Part(s)
Missing Fastener Unacceptable
No Cracking within or Adjacent to the

Cracks Weld are Permitted
Holes, or Burn-Throughs, in the Fastener

Holes or Substrate Material are Unacceptable
Max Deviation of Fastener Location from
Nominal Defined on Engineering :1
Location
Stud: 2mm
Nut: 1mm
> 75% Fusion of the Weldable area with
Fusion of Weldable Area the Mating part
1. Unless otherwise defined on the engineering drawing
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5.1.2 Bend Testing. Bend testing is a method of applying a load to the welded fastener to ensure
the welded joint can yield the desired performance without failure and not be damaged during
subsequent manufacturing processes. Bend test requirements are applicable to Weld Studs only
and shall be conducted with a torque wrench per ISO 14555, Section 11.3, Figure 3. The required
applied bending moment that must be applied to the stud is defined in Table 2. This load must be
applied with the stud showing no signs of cracking or permanent deformation of the stud or
substrate.
Table 2: Required Applied Moments for Stud Bend Testing
[Fastener Size] Bending Moment (N-m)
M5 4.1
M6 7.3
M8 17.3
M10 81
5.2 Destructive. Destructive testing is used to validate the performance of specific joining processes
prior to using said joining process to produce production assemblies. The number of destructive tests
required to validate a joining process as a part of Qualification is defined in Section 7. Destructive testing
may also be required as a part of on-going serial production.
5.2.1 Mechanical Properties. Table 3 defines the minimum and typical strength, Torque to failure
and Pull Off, requirements for Welded Fasteners produced to this specification. Where no
requirements are listed for a given fastener and substrate combination, refer to the engineering
drawing. Where no requirements are defined in this specification or the engineering drawing, the
supplier shall report the values recorded to Tesla for case-by-case approval. In any case, the failure
mode requirements in the following sub-sections are still required.
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TABLE 3: DESTRUCTIVE TEST REQUIREMENTS
[Fastener Type] [Fastener Size] Pull Off (N) Torque Off (N-m)
M5 8,520 8.0
M6 12,100 10.4
[Stud]
M8 22,000 25.0
M10 34,800 50.5
M5 4,500 35.0
[S-Nut] M6 5,000 50.0
M8 5,500 70.0
M5 4,500 35.0
M6 5,000 50.0
[H-Nut] M8 5,500 70.0
M10 7,000 105.0
M12 9,000 150.0
1. If failure occurs below these values, but still meet the requirements of Section 5.2.2, it shall be considered a pass.
5.2.2 Failure Mode. Upon destructive testing for mechanical properties, the failed samples shall be
visually inspected. The weld area shall show that the detached bolt has pulled a slug of the test
plate material out of the test plate at all weld projection points. This is not applicable if failure occurs
in the fastener provided the fastener properties are within specifications defined on the engineering
drawing for the fastener.
6 Test Methods
6.1 Test Setup. Pull Off and Torque Off testing on weld studs should be conducted similar to ISO 14555,
section 11.4 and 11.5, respectively. Pull Off and Torque Off testing on Weld Nuts should be conducted
similar to setup described in Figure 1. The fastener must have full thread engagement in both of these
tests. Tesla Quality Engineering shall approve the test method proposed by the manufacturer.
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FIGURE 1: WELD NUT TEST SETUP

A) PULL OFF TESTING SETUP B) TORQUE OFF TESTING SETUP
7 Qualification
This section defines the equipment and process qualification requirements prior to the start of
production in order to ensure manufacturing capabilities are able to meet engineering requirements.
7.1 Weld Schedule. Certified welding schedules for each unique fastener and substrate material
combination are required for welding production assemblies. Since most production assemblies will
not be configured in a way to yield the types and quantities of specimens required, simulated production
assembly parts can be produced for certification testing.
7.2 Test Requirements. Sample types and quantities for Weld Schedule Certification are defined in Table
4. Prepare test specimens and verify results meet the requirements of 5.
Table 4: MACHINE QUALIFICATION AND WELD SCHEDULE CERTIFICATION TEST REQUIREMENTS PER STACK-UP
Test1 Quantity
Torque Out 6
Pull Out 6
1. Visual inspection prior and post testing on each samples is also required.
8 Manufacturing Control
This section covers the Manufacturing controls necessary to ensure production processes are capable
of consistently meeting engineering requirements.
8.1 Dimensional. The following controls of dimensions and positional tolerances used for production
welding are required to ensure weld quality requirements are met
8.1.1 Standard. Tesla will interpret all dimensions on parts and assemblies using the ASME-Y14.5
2009 Standard
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8.1.2 Positional Tolerance. The dimensional requirement that must be achieved between the welded
fastener and the connecting hole is where the datum reference feature ‘A’ refers to the
threads of the fastener and is in reference to the hole feature. No material modifiers are allowed. The
process capability index for this requirement would need to be at 𝐶̂𝑝𝑘 =1.33 where the supplier is
required to report the measurement values to verify capability to Tesla.
8.1.3 Mating Hole Tolerance. Default tolerance for the connecting hole is ±0.1mm. Connecting hole
sizes and size tolerances are allowed to be modified from the recommended hole size in the Welded
Fasteners released drawings, at the supplier’s discretion, in order to yield the desired dimensional
requirements. Positional tolerance of the connecting holes are not allowed to be modified for the
purpose of achieving the dimensional requirement as stated in 8.1.2.
8.2 Material. The following controls of materials used for production welding are required to ensure
weld quality requirements are met.
8.2.1 Work Materials and Fasteners. Materials to be welded shall be kept in a clean, dry,
environment, free of unapproved contaminates that could adversely affect weld quality. The
presence of sealants, adhesives, coatings, press lube, mill oil, etc. are acceptable in the joint
provided they are included as part of the weld qualification testing per Section 7.1.
Note: High Strength Steel Alloys, greater than 1000MPa UTS, are particularly susceptible to
Hydrogen Embrittlement during elevated temperatures, such as those during welding processes.
The following precautions shall be incorporated as a part of regular production control to minimize
the risk of Hydrogen Embrittlement:
a. Materials must be clean and dry before welding.
b. Rust, dirt, grease and moisture around the welding area must be removed
c. Use dry consumables and low hydrogen electrodes
8.3 Equipment. The following controls of equipment used for production welding are required to ensure
weld quality requirements are met.
8.3.1 Welding Equipment. Welding equipment shall be able to reliably set and control, within +/-
2%, current, force, time and other parameters deemed critical to the process so that welds can be
consistently and reliably produced to meet the requirements of this specification. Weld jigs and
fixtures shall be nonmagnetic and so designed that welding current will not shunt through them
instead of passing through the work piece(s).
8.3.2 Testing Equipment. Calibrate testing machines used to evaluate weld strength at intervals
established by the responsively Quality Assurance in order to meet ISO 17025 requirements.
Calibrate testing equipment used to measure surface resistance at intervals established by Quality
Assurance.
8.4 Production Welding. The following manufacturing process controls shall be followed in order to
ensure production assemblies conform to qualification results and design requirements.
Use only certified production welding schedules. During production welding, the machine control
settings may be varied by +10% of the value specified on the certified weld schedule. Stop welding if
satisfactory welding cannot be maintained within the limits of allowable adjustment.
8.5 Inspection. Quality Assurance, or equivalent organization, shall ensure that the requirements of this
specification are met by monitoring the process and examining end-items in accordance with
established quality assurance methods. Quality Assurance is responsible and shall ensure that an
adequate system for monitoring, recording and processing all pertinent information has been
established. Specific inspection requirements are defined in the subsequent sub-sections. Inspection
frequencies defined here are baseline requirements, but may be modified at the discretion of Quality
Engineering.
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8.5.1 Process. Quality assurance shall check at random intervals to ensure that equipment is using
the proper Certified Welding Schedules on a Qualified machine. These checks should be
documented in an inspection record or on the manufacturing plan.
8.5.2 Non-Destructive Evaluation. Requirements for routine production non-destructive inspections

for weld quality per Section 5.2 are defined in Table 5.
Table 5: NON-DESTRUCTIVE PRODUCTION INSPECTION REQUIREMENTS
Test Frequency
Visual 1-Assy/day
Bend 1-Assy/day
8.5.3 Destructive Testing. Routine destructive testing, Torque to Failure and Pull Off, shall be
conducted at the discretion of Quality Assurance.
8.6 Rework. All non-conforming Weld Fasteners shall be re-worked. Approved re-work procedures
are defined in Table 6. Additional repair methods may be used at the discretion of Quality Engineering.
Table 6: NON-DESTRUCTIVE PRODUCTION INSPECTION REQUIREMENTS
Condition Repair Procedure
Remove Spatter from Threads by

Spatter Studs: Wire Brush
Nuts: Tap
Reprocess with Approved Weld Schedule,
or
(2) Arc Welds to Attach Fasteners to Parts
covering a minimum of 90deg of the
Missing Fastener Circumference and Opposite each other
or
Use a Rivet-Style Stud with Approval from
Design Engineering
Remove the miss located fastener and
Miss Located Fastener prep-surface for re-welding. Then follow
procedure for Missing Fastener.
Cracks / Holes Arc Welding to repair condition
Eruption Grinding to remove condition
Arc weld repair procedure defined for

Insufficient Weld Size Missing Fastener
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9 Document History
VERSION REVISOR DATE DESCRIPTION OF CHANGE
1 P. Edwards 2016-11-27 Initial Release
2 P. Edwards 2016-12-8 Revised Table 3 based on supplier feedback.
3 H. Quiroga 2017-5-23 Added CPK study requirement and weld nut test setup.
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TM-2508 Rev 3 Weld Stud and Nuts-Steel

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TM-2508

Weld Studs and Nuts - Steel

0 Overview & Guidance

WZ 100 Steel Metric Threaded Fasteners Torque/Clamping Force Performance

WE 960 Material and Performance Requirements of Weld Nuts

WA 960 Material and Performance Requirements of Weld Bolts

ISO 14555 Welding – Arc stud welding of metallic materials

Spatter: Weld expulsion metal that remains attached to adjacent surfaces.

[Fastener Type]-[Fastener Size]-[Weld Process]-[Material]-[Substrate Thickness]

[Stud] Weld Stud

[H-Nut] High Strength Hex Flange Weld Nut

[S-Nut] Low Strength Square Flange Weld Nut

[Arc] Drawn Arc Welding

[Projection] Resistance Projection, or Capacitive Discharge, Welding

[FeC] all steel alloys, and coatings, used by Tesla Motors.

5.1 Non-Destructive. Non-destructive evaluations are performed as a part of process qualification as

Table 1: VISUAL REQUIREMENTS

Spatter None on Threads

Acceptable Provided it Doesn’t Interfere

Missing Fastener Unacceptable

No Cracking within or Adjacent to the

Holes, or Burn-Throughs, in the Fastener

Table 2: Required Applied Moments for Stud Bend Testing

[Fastener Size] Bending Moment (N-m)

TABLE 3: DESTRUCTIVE TEST REQUIREMENTS

M10 34,800 50.5

[S-Nut] M6 5,000 50.0

[H-Nut] M8 5,500 70.0

M10 7,000 105.0

M12 9,000 150.0

FIGURE 1: WELD NUT TEST SETUP

a. Materials must be clean and dry before welding.

c. Use dry consumables and low hydrogen electrodes

8.5.2 Non-Destructive Evaluation. Requirements for routine production non-destructive inspections

Table 5: NON-DESTRUCTIVE PRODUCTION INSPECTION REQUIREMENTS

Table 6: NON-DESTRUCTIVE PRODUCTION INSPECTION REQUIREMENTS

Condition Repair Procedure

Remove Spatter from Threads by

Cracks / Holes Arc Welding to repair condition

Eruption Grinding to remove condition

Arc weld repair procedure defined for

VERSION REVISOR DATE DESCRIPTION OF CHANGE

1 P. Edwards 2016-11-27 Initial Release

2 P. Edwards 2016-12-8 Revised Table 3 based on supplier feedback.

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